KA24DE: Engine Basics and Specs
The KA24DE is a 2.4L inline four-cylinder engine that uses an iron cylinder block with an aluminum cylinder head. Part of the reason Nissan used an iron cylinder block was to save money. The engine was intended for use in light trucks and SUVs, so weight saving wasn’t a significant concern. Early versions of this engine used a SOHC design with three valves per cylinder. Even with its relatively large displacement, the KA24 did not implement balance shafts.

Later versions of this engine used a DOHC design with four valves per cylinder which increased power and efficiency. Oddly enough, Nissan decided to use a shim-over-bucket configuration for the valve train instead of rocker arms. The KA24 uses a Hitachi sequential electronic fuel injection system. Nissan configured some KA24 engines for front wheel drive vehicles.

Production Run: 1988 – 2004
Displacement: 2389cc
Cylinder Block Material: Cast Iron
Cylinder Head Material: Cast Aluminum
Valvetrain: SOHC | Three Valves per Cylinder (1988 – 1997) – DOHC | Four Valves per Cylinder (1991 – 2004)
Stroke: 96mm
Bore: 89mm
Compression Ratio: 8.6:1 to 9.5:1
Horsepower: 134hp to 155hp
Torque: 152 lb-ft to 160 lb-ft
Deck: Open Deck
Configuration: Inline Four Cylinder
Cars That Came With the KA24DE
Nissan put the KA24E and KA24DE in a variety of different products through their life cycles. Some engines were destined for light duty pickup trucks and SUVs such as the Nissan Hardbody or Nissan Xterra, but the KA24 is best known for its appearance in the 240SX. It makes sense just to adapt the engine for multiple platforms rather than creating an all-new engine.

1989 – 1990: Nissan 240 (KA24E)
1990 – 1997: Nissan Hardbody (KA24E)
1990 – 1995: Nissan Pathfinder (KA24E)
1989 – 1995: Nissan Access / Nissan Prairie (KA24E)
1990 – 1992: Nissan Stanza (KA24E)
1989 – 1992: Nissan Pintara / Ford Corsair (KA24E)
1993 – 1996: Nissan Terrano II (KA24E)
2000 – 2004: Nissan Xterra (KA24DE)
1998 – 2008: Nissan Frontier (KA24DE)
1991 – 1998: Nissan 240SX (KA24DE)
1997 – 2000: Nissan R’nessa (KA24DE)
1998 – 2001: Nissan Presage (KA24DE)
1999 – 2001: Nissan Bassara (KA24DE)
1993 – 1997: Nissan Bluebird (KA24DE)
1993 – 2001: Nissan Altima (KA24DE-a)
KA24DE: Known Problems
Just like any other engine, the KA24DE has a couple of known issues that are common. The distributor is known for failing on earlier versions of the KA24. Another prevalent issue is a rattling timing chain, which occurs when the timing chain gets loose from age and begins to rub against the timing chain cover.

Supposedly the alternator fails more than many other vehicles, but we are not able to verify this problem. The last issue is the valve cover gasket which is known for leaking, which is mostly due to the bolt pattern and design of the valve cover. It’s a pretty quick and easy fix, but it is a common occurrence.

KA24DE: Tuning Potential
Thanks to the massive explosion of drifting, the 240SX has become the most popular tuner car in the world. Although many people upgrade to the SR20DET engine, many stay with the KA24DE because of its larger displacement. A naturally aspirated built can reach up to 200whp (230bhp), but it isn’t cheap. This kind of build requires full bolt-on, ported and polished head, bigger cams, and possibly a higher compression ratio.

Many people prefer the turbocharged route as it’s relatively cheap and makes pretty decent amounts of power. Although many people use an eBay turbocharger or the SR20 turbo, the better option is to use a quality turbo. Something like a Garrett GTX2867R would easily make 400whp or more. If you want excellent throttle response and lot’s of low-end torque, a Borg Warner EFR turbo would be a great solution. Unfortunately, the stock bottom-end isn’t strong and can only hold up to about 350whp. If you’re looking to go for big power, you’ll need a forged rotating assembly. If you end up dumping that much money into a KA24, you might as well swap in a 1JZ/2JZ or RB engine which will make way more power while also being more reliable.

Ka24E vs KA24DE
There seems to be quite a lot of confusion about the differences between the KA24E and the KA24DE. As you may expect, these engines are very similar, but there are a few fundamental differences that separate these engines. The most significant difference is the cylinder head.

The Ka24E was a single overhead cam engine with just three valves per cylinder, and the KA24DE was a dual overhead cam engine with four valves per cylinder. If you didn’t already know, the biggest power gains of any engine are found in the cylinder head. It was mostly the trucks that use the KA24E, but the 89-90 240SX also used it. Luckily, the 1991 – 1998 240SX used the KA24DE.

Design improvements of the dual cam engine include the use of a knock sensor, larger diameter girdled main bearings in the Japanese block, different oil pan, different oil pickup, dipstick location, and piston oil squirters.

### Overhauling Gear Set on Nissan KA24DE

#### Tools Needed
1. **Socket Set** (Metric)
2. **Torque Wrench**
3. **Pliers**
4. **Screwdrivers** (Flathead and Phillips)
5. **Pick Tool**
6. **Gear Puller**
7. **Snap Ring Pliers**
8. **Dial Indicator**
9. **Feeler Gauges**
10. **Cleaning Supplies** (Brake Cleaner, Rags)
11. **Oil and Lubricants** (for assembly)
12. **Replacement Parts** (bearings, seals, gaskets as necessary)

#### Safety Precautions
1. **Wear Safety Glasses**: Protect your eyes from debris.
2. **Gloves**: Use gloves to protect your hands from sharp edges and chemicals.
3. **Work in a Well-Ventilated Area**: Prevent inhalation of fumes from cleaning agents.
4. **Secure Vehicle**: Ensure the vehicle is on a stable surface and use wheel chocks.

#### Step-by-Step Overhaul Process

1. **Preparation**:
- Disconnect the battery.
- Remove any necessary components to access the gear set (e.g., hood, air intake).

2. **Drain Fluids**:
- Drain engine oil and transmission fluid. Use a catch pan.

3. **Remove Gear Set**:
- Use socket set to unbolt the transmission from the engine.
- Carefully pull the transmission away; use a gear puller if necessary.

4. **Disassemble Gear Set**:
- Remove any snap rings using snap ring pliers.
- Use a pick tool to dislodge bearings and seals. Be cautious not to damage the housing.

5. **Clean Components**:
- Use brake cleaner and rags to clean all components thoroughly. Inspect for wear and damage.

6. **Inspect Gear Set**:
- Check gears for pitting, wear, and cracks. Use a dial indicator to measure any wear on gear teeth.

7. **Replace Worn Parts**:
- Replace bearings, seals, and gaskets as necessary. Ensure parts are OEM or equivalent quality.

8. **Reassemble Gear Set**:
- Apply oil to new bearings and seals before installation.
- Reinstall gears and secure with snap rings.

9. **Set Gear Backlash**:
- Use feeler gauges to check the backlash between gears. Adjust as necessary to manufacturer specifications.

10. **Reattach Transmission**:
- Align the transmission back to the engine and secure with bolts using a torque wrench to tighten to manufacturer specifications.

11. **Refill Fluids**:
- Refill the engine oil and transmission fluid with the recommended types and quantities.

12. **Reconnect Battery**:
- Reconnect the battery terminals.

13. **Test**:
- Start the engine and check for leaks. Test drive to ensure proper function.

#### Common Pitfalls to Avoid
- **Not Cleaning Components**: Failing to clean can lead to premature wear.
- **Incorrect Torque Specifications**: Always double-check torque specs; over-tightening can damage threads.
- **Ignoring Backlash Settings**: Improper backlash can lead to gear noise or failure.
- **Not Using the Right Tools**: Using improper tools can damage components.

#### Replacement Parts
- **Bearings**: Inspect and replace if worn.
- **Seals**: Replace to prevent fluid leaks.
- **Gaskets**: Always replace gaskets when disassembling the gear set.

By following these steps and precautions, you can successfully overhaul the gear set on a Nissan KA24DE while avoiding common mistakes.
rteeqp73

### Fusing on a Nissan KA24DE

#### Tools Needed:
- **Wrench Set (Metric)**: Used to loosen and tighten nuts and bolts. Ensure you have a set that includes various sizes (10mm, 12mm, 14mm, etc.) to fit the engine components you'll be working on.

- **Socket Set (Metric)**: Similar to the wrench set but allows for easier access to bolts in tight spaces. A ratchet handle will help speed up the process.

- **Torque Wrench**: Ensures that bolts are tightened to the manufacturer's specifications. This is crucial for engine components to prevent damage or failure.

- **Screwdriver Set**: Both flathead and Phillips screwdrivers are necessary to remove various screws and clips.

- **Pliers**: Useful for gripping and pulling components or wires. Needle-nose pliers can help with tight spaces.

- **Wire Stripper/Cutter**: Necessary if you need to cut or strip wires for electrical connections, especially when fusing.

- **Heat Shrink Tubing/ Electrical Tape**: Used to insulate electrical connections after fusing to prevent short circuits.

- **Soldering Iron and Solder**: If you're making permanent electrical connections, soldering is a reliable method for fusing wires together.

- **Multimeter**: To check electrical continuity and ensure connections are functioning properly.

#### Procedure:
- **Disconnect Battery**: Always disconnect the negative terminal of the battery first to prevent electrical shocks or shorts.

- **Identify Wires**: Determine which wires need to be fused. This may involve checking a wiring diagram specific to the KA24DE engine.

- **Cut Wires**: Use wire cutters to carefully cut the wires you intend to fuse. Ensure you have enough length to work with.

- **Strip Wire Ends**: Use a wire stripper to remove about 1/4 inch of insulation from both ends of the cut wires.

- **Twist Wires Together (if not soldering)**: Align the stripped ends of the wires and twist them together tightly.

- **Solder Wires (if using soldering)**: Heat the soldering iron, apply solder to the twisted wires, and allow it to cool to form a solid connection.

- **Insulate Connection**: Slide heat shrink tubing over the connection or wrap with electrical tape to prevent exposure and shorts.

- **Reconnect Battery**: Once all fusing is complete, reconnect the battery by connecting the positive terminal first, then the negative.

#### Replacement Parts:
- **Electrical Connectors**: If any connectors are damaged during the process, you may need to replace them to ensure a secure fit.

- **Fuses**: Check for any blown fuses in the fuse box after fusing. Replace them as necessary to ensure the electrical system functions properly.

- **Wires**: If wires are frayed or damaged beyond repair, consider replacing them with new wire of the same gauge.

#### Additional Notes:
- **Safety Gear**: Always wear gloves and safety glasses to protect yourself from electrical hazards and sharp components.

- **Consult Manual**: If unsure about any step, refer to the service manual for the Nissan KA24DE for specific instructions and torque specifications.

- **Practice Caution**: Take your time and double-check connections to avoid short circuits or engine damage.
rteeqp73

- **Tools Required:**
- **Socket Set (with Ratchet and Extensions):**
- Use sockets to remove bolts securing the starter motor. Ratchet helps turn the sockets easily; extensions help reach bolts in tight spaces.
- **Wrench Set:**
- Wrenches may be needed for bolts that are hard to reach with a socket. They provide a better grip in tight spaces.
- **Screwdriver Set:**
- Flathead and Phillips screwdrivers may be needed for any brackets or covers that need to be removed.
- **Pliers:**
- Useful for gripping and removing connectors if they are stuck or difficult to reach.
- **Multimeter (optional):**
- To check the electrical system if the starter motor is suspected to be faulty. It measures voltage and continuity.
- **Jack and Jack Stands:**
- Needed if you need to access the undercarriage for better access to the starter motor. Ensure safety by using jack stands.
- **Safety Goggles and Gloves:**
- Protects your eyes and hands while working.

- **Step-by-Step Instructions:**
- **Preparation:**
- Disconnect the negative battery terminal. This prevents electrical shocks and short circuits.

- **Accessing the Starter Motor:**
- Depending on your vehicle's configuration, you might need to remove the intake manifold or other components for better access.
- Use the socket set to remove any bolts or screws that hold these components in place.

- **Locating the Starter Motor:**
- The starter motor is typically located near the bottom of the engine, usually on the passenger side. It’s cylindrical and has wires connected to it.

- **Removing the Starter Motor:**
- Disconnect the electrical connections (two wires: a big one from the battery and a smaller one for the ignition signal). Use pliers if needed.
- Use a socket or a wrench to remove the bolts securing the starter motor to the engine block. Keep track of these bolts, as you will need them for the new starter.
- Carefully pull the starter motor out. Be cautious of any fluids or debris.

- **Inspecting the Starter Motor:**
- Check for any signs of damage, such as burnt connections or physical wear. If it appears damaged, replacement is necessary.

- **Replacement Part:**
- **Starter Motor:**
- If your inspection shows wear or malfunction, you will need a new starter motor. Ensure it’s compatible with the Nissan KA24DE engine.

- **Installing the New Starter Motor:**
- Position the new starter motor in place and align it with the bolt holes.
- Secure it with the bolts you previously removed. Use a socket or wrench to tighten them securely.
- Reconnect the electrical connections to the new starter, ensuring they are secure.

- **Reassembling Components:**
- Reinstall any components you removed for access, such as the intake manifold or covers, using your socket set and screwdrivers.

- **Final Steps:**
- Reconnect the negative battery terminal.
- Start the engine to ensure the new starter motor functions correctly.

- **Additional Notes:**
- If your vehicle does not start after replacement, check the battery condition and connections, as well as the ignition system. A multimeter can be used to diagnose electrical issues.
rteeqp73