Nissan Frontier D22. Instruction — part 204

SERVICE DATA AND SPECIFICATIONS (SDS)

CL-15

D

E

F

G

H

I

J

K

L

M

A

B

CL

SERVICE DATA AND SPECIFICATIONS (SDS)

PFP:00030

Clutch Control System

ECS007H3

Clutch Master Cylinder (with clutch damper)

ECS007H4

Clutch Operating Cylinder

ECS007H5

Clutch Disc

ECS007H6

Unit: mm (in)

Clutch Cover

ECS007H7

Unit: mm (in)

Clutch Pedal

ECS007H8

Unit: mm (in)

*: Measured from surface of dash lower panel to pedal pad.

Type of clutch control

Hydraulic

Inner diameter

15.87 mm (5/8 in)

Inner diameter

19.05 mm (3/4 in)

Model

240

250

250

Engine

KA24DE

VG33E

VG33ER

Facing size
(Outer dia. x inner dia. x thickness)

240 x 150 x 3.5

(9.45 x 5.91 x 0.138)

250 x 160 x 3.5

(9.84 x 6.30 x 0.138)

250 x 160 x 3.5

(9.84 x 6.30 x 0.138)

Thickness of disc assembly with load

7.75 - 8.25 (0.305 -

0.3248)

with 4,903 N (500 kg,

1,103 lb)

8.1 - 8.5 (0.3189 -

0.3346)

with 6,473 N (660 kg,

1,455 lb)

8.1 - 8.5 (0.3189 -

0.3346)

with 4,903 N (500 kg,

1,103 lb)

Wear limit of facing surface to rivet head

0.3 (0.012)

0.3 (0.012)

0.3 (0.012)

Runout limit of facing

1.0 (0.039)

1.0 (0.039)

1.0 (0.039)

Distance of runout check point (from hub center)

115 (4.53)

120 (4.72)

120 (4.72)

Maximum backlash of spline (at outer edge of disc)

1.0 (0.039)

1.0 (0.039)

1.0 (0.039)

Engine

KA24DE

VG33E

VG33ER

Model

240

250

250

Set-load

2WD

4,903 N (500 kg, 1,103 lb)

6,473 N (660 kg, 1,455 lb)

7,355 N (750 kg, 1,653 lb)

4WD

—

6,473 N (660 kg, 1,455 lb)

7,355 N (750 kg, 1,653 lb)

Diaphragm spring height

37.5 - 39.5 (1.476 - 1.555)

36.5 - 38.5 (1.437 -

1.516)

37 - 39 (1.457 - 1.535)

Uneven limit of diaphragm spring toe height

0.7 (0.028)

0.5 (0.020)

0.7 (0.028)

Clearance between pedal stopper bracket and clutch interlock
switch (with clutch pedal fully depressed.)

0.1 - 1.0 (0.004 - 0.039)

CL-16

SERVICE DATA AND SPECIFICATIONS (SDS)

CO-1

ENGINE COOLING SYSTEM

B ENGINE

CONTENTS

C

D

E

F

G

H

I

J

K

L

M

SECTION

A

CO

KA24DE

PRECAUTIONS . . . . . . . . . . . . . . .. 3

Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” . . . . . . . . . . . . . . . . .. 3
Precautions for Liquid Gasket . . . . . . . . .. 3

REMOVAL OF LIQUID GASKET . . . . . . .. 3
LIQUID GASKET APPLICATION PROCEDURE

. . 4

PREPARATION . . . . . . . . . . . . . . ... 5

Special Service Tools . . . . . . . . . . . ... 5

OVERHEATING CAUSE ANALYSIS . . . . . . .. 6

Troubleshooting Chart . . . . . . . . . . . .. 6

COOLING SYSTEM . . . . . . . . . . . . . 7

Cooling Circuit . . . . . . . . . . . . . . .. 7

ENGINE COOLANT . . . . . . . . . . . . . 8

System Check . . . . . . . . . . . . . . .. 8

CHECKING COOLING SYSTEM HOSES . . . 8
CHECKING RADIATOR . . . . . . . . . . 8
CHECKING COOLING SYSTEM FOR LEAKS . . 8
CHECKING RADIATOR CAP . . . . . . . . 8

Refilling Engine Coolant . . . . . . . . . . ... 9

WATER PUMP . . . . . . . . . . . . . . .. 10

Removal . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . ...11

THERMOSTAT . . . . . . . . . . . . . . .. 13

Removal . . . . . . . . . . . . . . . . . 13
Inspection . . . . . . . . . . . . . . . ... 13
Installation . . . . . . . . . . . . . . . .. 13

RADIATOR . . . . . . . . . . . . . . . . 14

Components . . . . . . . . . . . . . . ... 14
Removal and Installation . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . ... 15

COOLING FAN (CRANKSHAFT DRIVEN) . . . .. 16

Removal and Installation . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . ... 16

SERVICE DATA AND SPECIFICATIONS (SDS) . .. 17

Thermostat . . . . . . . . . . . . . . . . 17
Radiator . . . . . . . . . . . . . . . . .. 17

VG33E and VG33ER

PRECAUTIONS . . . . . . . . . . . . . . 18

Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” . . . . . . . . . . . . . . . . . 18
Precautions for Liquid Gasket . . . . . . . . 18

REMOVAL OF LIQUID GASKET . . . . . . . 18

Precautions for Liquid Gasket . . . . . . . . 19

REMOVAL OF LIQUID GASKET . . . . . . . 19
LIQUID GASKET APPLICATION PROCEDURE ... 19

PREPARATION . . . . . . . . . . . . . . . 20

Special Service Tools . . . . . . . . . . . . 20

OVERHEATING CAUSE ANALYSIS . . . . . . 21

Troubleshooting Chart . . . . . . . . . . . 21

COOLING SYSTEM . . . . . . . . . . . . .. 22

Cooling Circuit . . . . . . . . . . . . . . 22

ENGINE COOLANT . . . . . . . . . . . . .. 23

System Check . . . . . . . . . . . . . . 23

CHECKING COOLING SYSTEM HOSES . . ... 23
CHECKING RADIATOR . . . . . . . . . .. 23
CHECKING COOLING SYSTEM FOR LEAKS ... 23
CHECKING RADIATOR CAP . . . . . . . .. 23

Refilling Engine Coolant . . . . . . . . . . . 24

WATER PUMP . . . . . . . . . . . . . . .. 25

Removal . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . ... 26
Installation . . . . . . . . . . . . . . . .. 26

THERMOSTAT . . . . . . . . . . . . . . .. 28

Removal . . . . . . . . . . . . . . . . . 28
Inspection . . . . . . . . . . . . . . . ... 28
Installation . . . . . . . . . . . . . . . .. 29

RADIATOR . . . . . . . . . . . . . . . . 30

Components . . . . . . . . . . . . . . ... 30
Removal and Installation . . . . . . . . . . 30
Inspection . . . . . . . . . . . . . . . ... 31

COOLING FAN (CRANKSHAFT DRIVEN) . . . ... 32

Removal and Installation . . . . . . . . . . 32
Inspection . . . . . . . . . . . . . . . ... 32

CO-2

SERVICE DATA AND SPECIFICATIONS (SDS) . .. 33

Thermostat . . . . . . . . . . . . . . . .. 33
Radiator . . . . . . . . . . . . . . . . .. 33