Nissan D21 Truck Service Manual, 1986–1997

Nissan’s 1997 D21 Truck factory service manual covers North American KA24E models with 2WD or 4WD, in Regular Cab and King Cab configurations. The publication carries a 1996 copyright and documents maintenance, fault diagnosis, and mechanical repair.

PDF Search, Bookmarks and Diagram Detail

Search and navigation: Main-manual text is not searchable; usable text search is limited to the GST attachment. Chapter and topic bookmarks are included, although some quick-reference links point to separate files. Small connector numbers and wire codes in dense diagrams require zooming.

Supplied as one printable, 1,236-page PDF in English. The total includes a one-page GST Mode 6 attachment, a one-page feedback form, a one-page quick-reference chart, and five electrical foldout/reference pages.

KA24E Repair, Driveline Overhaul and Circuit Diagnosis

These selected coverage highlights show the main workshop areas. Further topics include windshield water-leak repair and automatic speed control diagnosis.

• Engine repair: Step-by-step procedures for timing-chain replacement, cylinder-head overhaul, engine removal, and cylinder-block disassembly, with inspection limits and assembly specifications.

• Lubrication and cooling: Oil-pressure checks, oil-pump inspection, water-pump service, thermostat testing, radiator work, and overheating cause analysis.

• Engine control and fuel: Diagnostic trouble code confirmation, EVAP leak diagnosis, injector removal and installation, fuel-pressure checks, and fuel-tank service.

• Transmission and clutch: Manual and automatic transmission overhaul, hydraulic clutch service, shift-lock diagnosis, and automatic transmission stall and pressure testing.

• Transfer and final drive: Transfer-case overhaul, propeller-shaft inspection, differential adjustment, bearing-preload checks, and limited-slip differential service.

• Brakes, steering and suspension: Brake bleeding, rear-wheel ABS diagnosis, steering-gear repair, wheel-bearing adjustment, and front and rear suspension service.

• Electrical and climate control: Starting and charging tests, SRS diagnosis, harness layouts, connector views, and heater and air-conditioning fault tracing.

This manual suits technicians familiar with mechanical measurement and electrical diagnosis; its SRS precautions require maintenance by an authorized Nissan dealer.

Engine Inspection and Assembly Details

The engine chapters cover valve guides and seats, camshaft inspection, piston and cylinder measurements, crankshaft inspection, and oil-seal replacement. Exploded views identify lubrication points and tightening specifications, while component sections provide the associated inspection and assembly procedures.

The timing-chain chapter warns that independent crankshaft and camshaft rotation after chain removal can cause valve-to-piston contact. The cylinder-head section also addresses air entering hydraulic lifters when rocker assemblies are laid on their sides, with checks for noisy lifter operation.

Engine Control and Fuel-System Diagnosis

DTC sections combine confirmation criteria, ECM terminal reference values, wiring diagrams, and component checks. Diagnostic worksheets connect the reported symptoms and freeze-frame data to the relevant tests, helping technicians narrow a fault to its circuit or component.

EVAP coverage distinguishes small-leak diagnosis from purge-flow, vent-valve, and pressure-sensor faults. Fuel-system procedures include pressure-release precautions, injector service, and pump and gauge-unit work.

Transmission, Transfer and Differential Work

The FS5W71C sections distinguish 2WD and 4WD gear components. RL4R01A coverage extends to the oil pump, control valve bodies, clutch assemblies, governor, and assembly adjustments, supported by hydraulic control circuits and a transmission cross-sectional view.

Final-drive chapters separate the R180A front unit from the H190A, C200, and H233B rear units. They include pinion-height adjustment, tooth-contact checks, shim or washer selection, and limited-slip component inspection.

Chassis, Brakes and Steering

Chassis coverage distinguishes manual-lock and auto-lock front hubs, torsion-bar front suspension, and rear leaf-spring assemblies. Brake sections address the 2WD load-sensing valve and 4WD proportioning valve, alongside front disc brakes, rear drums, and rear-wheel ABS.

Steering chapters cover VB66K manual steering and PB59K and PB48S power-steering assemblies. Working on drivetrain components and heavy suspension systems carries physical risks; follow the manual’s vehicle-support and lifting precautions.

Electrical, Body and Air-Conditioning References

System-specific diagrams include POWER, START, CHARGE, ABS, and SRS. Harness layouts, switch diagrams, connector views, and Super Multiple Junction terminal arrangements support tracing connections between circuits and components.

Body and trim sections include instrument-panel removal, cab and rear-body work, and body-alignment measurements. Air-conditioning coverage adds refrigerant leak testing, abnormal-pressure diagnosis, control-linkage adjustment, and compressor-clutch service.

Examples of KA24E Bearing and Valve-Guide Specifications

For bottom-end inspection, standard main-bearing clearance is 0.020–0.047 mm. The accompanying bearing-selection information relates bearing grades to cylinder-block and crankshaft-journal grades.

At the cylinder head, standard intake-valve stem-to-guide clearance is 0.020–0.053 mm. Intake and exhaust specifications are listed separately, alongside wear limits and valve-guide replacement procedures.