Nissan Frontier D22. Manual — part 673

EXTERIOR

EI-35

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D

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A

B

EI

WBT162

LBT163

EI-36

CAB AND REAR BODY

CAB AND REAR BODY

PFP:93020

Body Mounting

EIS002DR

When removing, be sure to replace bolts and nuts (sealant applied bolts or self-lock nuts are used for all
mounting).

LBT190

EM-1

ENGINE MECHANICAL

B ENGINE

CONTENTS

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SECTION

A

EM

KA24DE

PRECAUTIONS . . . . . . . . . . . . . . .. 4

Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” . . . . . . . . . . . . . . . . .. 4
Parts Requiring Angular Tightening . . . . . . . 4
Precautions for Liquid Gasket . . . . . . . . .. 5

REMOVAL OF LIQUID GASKET SEALING . . .. 5
LIQUID GASKET APPLICATION PROCEDURE

. . 5

PREPARATION . . . . . . . . . . . . . . ... 6

Special Service Tools . . . . . . . . . . . ... 6
Commercial Service Tools . . . . . . . . . . 8

NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . ...11

Noise, Vibration and Harshness (NVH) . . . . ...11

NVH TROUBLESHOOTING CHART — ENGINE
NOISE . . . . . . . . . . . . . . . . . 12

OUTER COMPONENT PARTS . . . . . . . . 13

Removal and Installation . . . . . . . . . . 13

OIL PAN . . . . . . . . . . . . . . . . . 16

Components . . . . . . . . . . . . . . ... 16
Removal . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . .. 17

TIMING CHAIN . . . . . . . . . . . . . . . 19

Components . . . . . . . . . . . . . . ... 19

LIQUID GASKET APPLICATION PLACES . . . 20

Removal . . . . . . . . . . . . . . . . . 20

UPPER TIMING CHAIN . . . . . . . . . .. 21
IDLER SPROCKET . . . . . . . . . . . . 21
LOWER TIMING CHAIN . . . . . . . . . . 22

Inspection . . . . . . . . . . . . . . . ... 24
Installation . . . . . . . . . . . . . . . .. 24

LOWER TIMING CHAIN . . . . . . . . . . 24
IDLER SPROCKET . . . . . . . . . . . . 26
UPPER TIMING CHAIN . . . . . . . . . .. 26

OIL SEAL . . . . . . . . . . . . . . . . .. 28

Replacement . . . . . . . . . . . . . . .. 28

VALVE OIL SEAL . . . . . . . . . . . . 28
FRONT OIL SEAL . . . . . . . . . . . ... 28
REAR OIL SEAL . . . . . . . . . . . . . 30

CYLINDER HEAD . . . . . . . . . . . . . . 32

On-Vehicle Service . . . . . . . . . . . . . 32

CHECKING COMPRESSION PRESSURE . . . 32

Components . . . . . . . . . . . . . . ... 33
Removal . . . . . . . . . . . . . . . . . 33
Disassembly . . . . . . . . . . . . . . ... 34
Inspection . . . . . . . . . . . . . . . ... 34

CYLINDER HEAD DISTORTION . . . . . . 34
CAMSHAFT VISUAL CHECK . . . . . . . . 35
CAMSHAFT RUNOUT . . . . . . . . . . 35
CAMSHAFT CAM HEIGHT . . . . . . . . . 35
CAMSHAFT JOURNAL CLEARANCE . . . . 36
CAMSHAFT END PLAY . . . . . . . . . .. 36
CAMSHAFT SPROCKET RUNOUT . . . . . 36
VALVE GUIDE CLEARANCE . . . . . . . .. 37
VALVE GUIDE REPLACEMENT . . . . . . . 37
VALVE SEATS . . . . . . . . . . . . . . 39
REPLACING VALVE SEAT . . . . . . . . . 39
VALVE DIMENSIONS . . . . . . . . . . .. 40
VALVE SPRING . . . . . . . . . . . . ... 40
VALVE LIFTER AND ADJUSTING SHIM . . . 41

Assembly . . . . . . . . . . . . . . . . 42
Installation . . . . . . . . . . . . . . . .. 42
Valve Clearance . . . . . . . . . . . . . . 43

CHECKING . . . . . . . . . . . . . . . 43
ADJUSTING . . . . . . . . . . . . . . 44

ENGINE ASSEMBLY . . . . . . . . . . . . 46

Removal and Installation . . . . . . . . . . 46

REMOVAL . . . . . . . . . . . . . . ... 47
INSTALLATION . . . . . . . . . . . . ... 47

CYLINDER BLOCK . . . . . . . . . . . . .. 48

Components . . . . . . . . . . . . . . ... 48
Removal and Installation . . . . . . . . . . 49
Disassembly . . . . . . . . . . . . . . ... 49

PISTON AND CRANKSHAFT . . . . . . . . 49

Inspection . . . . . . . . . . . . . . . ... 50

PISTON AND PISTON PIN CLEARANCE . . .. 50
PISTON RING SIDE CLEARANCE . . . . . . 51
PISTON RING END GAP . . . . . . . . . 51
CONNECTING ROD BEND AND TORSION . .. 51

EM-2

CYLINDER BLOCK DISTORTION AND WEAR ... 52
PISTON-TO-CYLINDER BORE CLEARANCE . 52
CRANKSHAFT . . . . . . . . . . . . . 53
BEARING CLEARANCE . . . . . . . . . . 54
CONNECTING ROD BUSHING CLEARANCE
(SMALL END) . . . . . . . . . . . . . .. 57
REPLACEMENT OF CONNECTING ROD
BUSHING (SMALL END) . . . . . . . . . 58
FLYWHEEL/DRIVE PLATE RUNOUT . . . . . 58

Assembly . . . . . . . . . . . . . . . . 58

PISTON . . . . . . . . . . . . . . . ... 58
CRANKSHAFT . . . . . . . . . . . . . 60
REPLACING PILOT BUSHING . . . . . . ... 61

SERVICE DATA AND SPECIFICATIONS (SDS) . .. 63

General Specifications . . . . . . . . . . . 63

COMPRESSION PRESSURE . . . . . . . . 63

Cylinder Head . . . . . . . . . . . . . . . 63
Valve . . . . . . . . . . . . . . . . . ... 63

VALVE . . . . . . . . . . . . . . . . .. 63
VALVE SPRING . . . . . . . . . . . . ... 64
VALVE GUIDE . . . . . . . . . . . . . . 64
VALVE LIFTER . . . . . . . . . . . . . 64
VALVE CLEARANCE ADJUSTMENT . . . . . 65
AVAILABLE SHIMS . . . . . . . . . . . . 65
VALVE SEAT . . . . . . . . . . . . . ... 66

Cylinder Block . . . . . . . . . . . . . . . 67
Camshaft and Camshaft Bearing . . . . . . ... 68
Piston, Piston Ring and Piston pin . . . . . . . 69

PISTON . . . . . . . . . . . . . . . ... 69
PISTON PIN . . . . . . . . . . . . . . 69
PISTON RING . . . . . . . . . . . . . . 69

Connecting Rod . . . . . . . . . . . . . .. 70
Crankshaft . . . . . . . . . . . . . . . .. 70
Bearing Clearance . . . . . . . . . . . . .. 71
Available Main Bearing . . . . . . . . . . ... 71

STANDARD . . . . . . . . . . . . . . . 71
UNDERSIZE (SERVICE) . . . . . . . . . . 71

Available Connecting Rod Bearing . . . . . . . 71

STANDARD . . . . . . . . . . . . . . . 71
UNDERSIZE (SERVICE) . . . . . . . . . . 71

Miscellaneous Components . . . . . . . . . 71

VG33E and VG33ER

PRECAUTIONS . . . . . . . . . . . . . . . 72

Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” . . . . . . . . . . . . . . . . . 72
Parts Requiring Angular Tightening . . . . . . 72
Precautions for Liquid Gasket . . . . . . . . 73

REMOVAL OF LIQUID GASKET SEALING . . 73
LIQUID GASKET APPLICATION PROCEDURE ... 73

PREPARATION . . . . . . . . . . . . . . . 74

Special Service Tools . . . . . . . . . . . . 74
Commercial Service Tools . . . . . . . . . .. 76

NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . .. 78

Noise, Vibration and Harshness (NVH) . . . . .. 78

NVH TROUBLESHOOTING CHART — ENGINE

NOISE . . . . . . . . . . . . . . . . ..79

OUTER COMPONENT PARTS . . . . . . . . .80

Removal and Installation . . . . . . . . . . .80

OIL PAN . . . . . . . . . . . . . . . . . .88

Removal . . . . . . . . . . . . . . . . ..88
Installation . . . . . . . . . . . . . . . ...89

TIMING BELT . . . . . . . . . . . . . . . 91

Components . . . . . . . . . . . . . . . 91
Removal . . . . . . . . . . . . . . . . ..91
Inspection . . . . . . . . . . . . . . . . 93

BELT TENSIONER AND TENSIONER SPRING ...94

Installation . . . . . . . . . . . . . . . ...94
Tension Adjustment . . . . . . . . . . . . .95

AFTER BELT REPLACEMENT . . . . . . ...95
AFTER ENGINE OVERHAUL OR ENGINE
REASSEMBLY (WITH ROCKER COVERS
REMOVED) . . . . . . . . . . . . . . ..96

OIL SEAL . . . . . . . . . . . . . . . . ..99

Replacement . . . . . . . . . . . . . . ...99

VALVE OIL SEAL . . . . . . . . . . . . .99
CAMSHAFT OIL SEAL . . . . . . . . . . 99
FRONT OIL SEAL . . . . . . . . . . . ..100
REAR OIL SEAL . . . . . . . . . . . . 101

CYLINDER HEAD . . . . . . . . . . . . ...102

Measurement of Compression . . . . . . . ..102
Components . . . . . . . . . . . . . . ..104
Removal . . . . . . . . . . . . . . . . 105
Disassembly . . . . . . . . . . . . . . ..108
Inspection . . . . . . . . . . . . . . . .. 110

CYLINDER HEAD DISTORTION . . . . . ... 110
CAMSHAFT VISUAL CHECK . . . . . . . 110
CAMSHAFT RUNOUT . . . . . . . . . ... 110
CAMSHAFT CAM HEIGHT . . . . . . . . 110
CAMSHAFT JOURNAL CLEARANCE . . . .. 111
CAMSHAFT END PLAY . . . . . . . . . . 111
CAMSHAFT SPROCKET RUNOUT . . . . .. 111
VALVE GUIDE CLEARANCE . . . . . . . 112
VALVE GUIDE REPLACEMENT . . . . . ... 113
VALVE SEATS . . . . . . . . . . . . ... 114
REPLACING VALVE SEAT FOR SERVICE
PARTS . . . . . . . . . . . . . . . ... 114
VALVE DIMENSIONS . . . . . . . . . . 115
VALVE SPRING . . . . . . . . . . . . . 115
ROCKER SHAFT AND ROCKER ARM . . . . 116
HYDRAULIC VALVE LIFTER . . . . . . . . 116

Assembly . . . . . . . . . . . . . . . .. 117
Installation . . . . . . . . . . . . . . . . 118

SUPERCHARGER . . . . . . . . . . . . ..124

Components . . . . . . . . . . . . . . ..124
Removal . . . . . . . . . . . . . . . . 125
Inspection . . . . . . . . . . . . . . . ..126

SUPERCHARGER FLANGE . . . . . . . .126
ROTOR SYSTEM . . . . . . . . . . . ..126
SUPERCHARGER BYPASS VALVE ACTUA-
TOR . . . . . . . . . . . . . . . . ...126

Installation . . . . . . . . . . . . . . . .127