2006 NISSAN FRONTIER Service Repair Manual by 163615

QUICK REFERENCE INDEX Edition: September 2005 Revision: September 2005 Publication No. SM6E-1D40U0

A GENERAL INFORMATION

General Information

B ENGINE

Engine Mechanical

Engine Lubrication System

Engine Cooling System

Engine Control System

Fuel System

Exhaust System

ACC

TRANSMISSION/ TRANSAXLE

D DRIVELINE/AXLE

E SUSPENSION

F BRAKES

Accelerator Control System

Clutch

Manual Transmission

Automatic Transmission

Transfer

Propeller Shaft

FFD

Front Final Drive

RFD

Rear Final Drive

FAX

Front Axle

RAX

Rear Axle

FSU

Front Suspension

RSU

Rear Suspension

Road Wheels & Tires

Brake System

Parking Brake System

BRC

Brake Control System

G STEERING

Power Steering System

H RESTRAINTS

Seat Belts

SRS

BODY

J AIR CONDITIONER K ELECTRICAL

Supplemental Restraint System (SRS)

Body, Lock & Security System

Glasses, Window System & Mirrors

Roof

Exterior & Interior

Instrument Panel

Seat

MTC

Manual Air Conditioner

Starting & Charging System

Lighting System

Driver Information System

Wiper, Washer & Horn

BCS

Body Control System

LAN

LAN System

AV ACS

Audio Visual & Telephone System Auto Cruise Control System

Power Supply, Ground & Circuit Elements

L MAINTENANCE

Maintenance

M INDEX

IDX

Alphabetical Index

Â© 2005 NISSAN NORTH AMERICA, INC. All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photo-copying, recording or otherwise, without the prior written permission of Nissan North America, Inc., Gardena, California. -1

A B C D E F G H I J K L M

This manual contains maintenance and repair procedures for the 2006 NISSAN FRONTIER. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.

IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the vehicleâ&#x20AC;&#x2122;s safety will be jeopardized by the service method selected.

-2

QUICK REFERENCE CHART: FRONTIER

2006

QUICK REFERENCE CHART: FRONTIER Engine Tune-Up Data

PFP:00000 ELS001KR

QR25DE Engine Specifications Cylinder arrangement

In-line 4 2,488 cm3 (151.82 in3 )

Displacement Bore and stroke

89.0 x 100.0 mm (3.504 x 3.937 in)

Valve arrangement

DOHC

Firing order

1-3-4-2 Compression

Number of piston rings

Oil

Compression ratio

9.5:1

Compression pressure

Standard

1,304 kPa (13.3 kg/cm2 , 189 psi)/250 rpm

Minimum

1,108 kPa (11.3 kg/cm2 , 161 psi)/250 rpm

Differential limit between cylinders

100 kPa (1.0 kg/cm2 , 14 psi)/250 rpm

Valve timing

PBIC0187E

Unit: degree a

236°

224°

-4°

60°

32°

37°

VQ40DE Engine Specifications Cylinder arrangement

V-6 3,954 cm3 (241.30 in3 )

Displacement

95.5 × 92.0 mm (3.76 × 3.622 in)

Bore and stroke Valve arrangement

DOHC

Firing order Number of piston rings

1-2-3-4-5-6 Compression

Oil

Number of main bearings

Compression ratio

Compression pressure

9.7:1 Standard

1,275 kPa (13.0 kg/cm2 , 185 psi)/300 rpm

Minimum

981 kPa (10.0 kg/cm2 , 142 psi)/300 rpm

Differential limit between cylinders

98 kPa (1.0 kg/cm2 , 14 psi)/300 rpm

QUICK REFERENCE CHART: FRONTIER 2006

Cylinder number

SEM713A

Valve timing (Intake valve timing control - “OFF”)

PBIC0187E

Unit: degree a

244°

240°

−4°

64°

6°

58°

QR25DE and VQ40DE Engine Drive Belt Deflection and Tension Tension of drive belt

Auto adjustment by auto-tensioner

QR25DE Engine Spark Plugs (Double Platinum Tipped) Make

NGK

Standard type

PLZKAR6A-11

Hot type

PLZKAR5A-11

Cold type

PLZKAR7A-11

Gap (nominal)

1.1 mm (0.043 in)

VQ40DE Engine Spark Plugs (Double Platinum Tipped) Make

NGK

Standard type

PLFR5A-11

Hot type

PLFR4A-11

Cold type

PLFR6A-11

Gap (nominal)

1.1 mm (0.043 in)

Wheel Alignment (Unladen*1 )*6

ELS001KS

Drive type

Camber Degree minute (decimal degree)

2WD

4WD

Minimum

-0° 30′ (-0.50°)

-0° 15′ (-0.25°)

Nominal

0° 15′ (0.25°)

0° 30′ (0.50°)

Maximum Cross camber

1° 0′ (1.00°)

1° 15′ (1.25°)

0° 45′ (0.75°) or less

QUICK REFERENCE CHART: FRONTIER 2006 Drive type

Caster Degree minute (decimal degree)

2WD

4WD

Minimum

2° 15′ (2.25°)

2° 0′ (2.00°)

Nominal

3° 0′ (3.00°)

2° 45′ (2.75°)

Maximum

3° 45′ (3.75°)

3° 30′ (3.50)

0° 45′ (0.75°) or less

13° 0′ (13.00°)

12° 45′ (12.75°)

Cross caster Kingpin inclination Degree minute (decimal degree)

Nominal

SFA234AC

Distance (A − B)

2.1 mm (0.08 in)

3.1 mm (0.12 in)

4.1 mm (0.16 in)

0° 5′ (0.08°)

0° 7′ (0.12°)

Total toe-in Angle (left wheel or right wheel) Degree minute (Decimal degree)

0° 9′ (0.15°)

Inside Degree minute (Decimal degree)

33° 26′ – 35° 26′ * (33.43° – 35.43°)

33° 36′ – 35° 36′ *4 (33.60° – 35.60°)

Outside Degree minute (Decimal degree)

29° 22′ – 31° 22′ *3 (29.37° – 31.37°)

29° 44′ – 31° 44′ *5 (29.73° – 31.73°)

Wheel turning angle (full turn)

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: Target value 35° 26′ (35.43°) *3: Target value 31° 22′ (31.37°) *4: Target value 35° 36′ (35.60°) *5: Target value 31° 44′ (31.73°) *6: Some vehicles may be equipped with straight (non-adjustable) lower link bolts and washers. In order to adjust camber and caster on these vehicles, first replace the lower link bolts and washers with adjustable (cam) bolts and washers.

Brake

ELS001KU

Unit: mm (in) Engine Front brake

QR25DE Brake model Rotor outer diameter × thickness Pad Length × width × thickness Cylinder bore diameter (Dual piston)

Rear brake

Brake model Rotor outer diameter × thickness Pad Length × width × thickness Cylinder bore diameter (Single piston)

Control valve

VQ40DE

Valve model

CLZ33VB 283 × 18 (11.14 × 0.71)

296 × 28 (11.65 × 1.10)

140 × 49 × 10 (5.51 × 1.93 × 0.39) 46.4 (1.83) CLZ11VA 286 × 18 (11.26 × 0.71) 87.6 × 35 × 11 (3.45 × 1.38 × 0.433) 38.1 (1.50) EBD

QUICK REFERENCE CHART: FRONTIER 2006 Brake booster

Booster model

C215T

Diaphragm diameter Recommended brake fluid

215 (8.46) Genuine NISSAN Super Heavy Duty Brake Fluid or equivalent DOT 3 (US FMVSS No. 116)

Disc Brake - Repair Limits

ELS001KV

FRONT DISC BRAKE QR25DE Unit: mm (in) Brake model Brake pad

Disc rotor

CLZ33VB Standard thickness (new)

10 (0.394)

Repair limit thickness

2 (0.079)

Standard thickness (new)

18 (0.71)

Repair limit thickness

16 (0.630)

Maximum uneven wear (measured at 8 positions)

0.015 (0.0006)

Runout limit (with it attached to the vehicle)

0.05 (0.0020)

VQ40DE Unit: mm (in) Brake model Brake pad

Disc rotor

CLZ33VB Standard thickness (new)

10 (0.394)

Repair limit thickness

2 (0.079)

Standard thickness (new)

28 (1.10)

Repair limit thickness

26 (1.024)

Maximum uneven wear (measured at 8 positions)

0.015 (0.0006)

Runout limit (with it attached to the vehicle)

0.05 (0.0020)

REAR DISC BRAKE Unit: mm (in) Brake model Brake pad

Disc rotor

CLZ11VA Standard thickness (new)

11 (0.433)

Repair limit thickness

2 (0.079)

Standard thickness (new)

18 (0.71)

Repair limit thickness

16 (0.630)

Maximum uneven wear (measured at 8 positions)

0.015 (0.0006)

Runout limit (with it attached to the vehicle)

0.07 (0.0028)

QUICK REFERENCE CHART: FRONTIER 2006

Brake Pedal

ELS001KW

Unit: mm (in)

WFIA0160E

Free height "H"

A/T

182.1 - 192.1 (7.17 - 7.56)

M/T

174.7 - 184.7 (6.88 - 7.27)

Depressed pedal height ("D" [under a force of 490 N (50 kg, 110 lb) with engine running] Clearance between pedal stopper and threaded end of stop lamp switch and ASCD switch "C1 " or “C2 ” Pedal play "A"

103 - 123 (4.06 - 4.84) 0.74 - 1.96 (0.029 - 0.077) 3 - 11 (0.12 - 0.43)

QUICK REFERENCE CHART: FRONTIER 2006

Refill Capacities

ELS001KX

QR25DE Engine Capacity (Approximate) Description

Metric

US measure

Imp measure

21 1/8 gal

17 5/8 gal

With oil filter change

4.9

5 1/8 qt

4 3/8 qt

Without oil filter change

4.6

4 7/8 qt

4 qt

5.0

5 1/4 qt

4 3/8 qt

9.4

2 1/2 gal

2 1/8 gal

Automatic transmission fluid (ATF)

10.3

10 7/8 qt

9 1/8 qt

Manual transmission fluid (MTF) (5 M/T)

2.89

6 1/8 pt

5 1/8 pt

1.6

3 3/8 pt

2 7/8 pt

Power steering fluid (PSF)

1.0

2 1/8 pt

1 3/4 pt

Windshield washer fluid

4.5

1 1/4 gal

1 gal

1.54 ± 0.11 lb

6.1 fl oz

6.3 fl oz

Fuel Engine oil Drain and refill Dry engine (engine overhaul) Cooling system

Rear final drive oil

With reservoir at MAX level

C200

0.70 ± 0.05 kg

Air conditioning system refrigerant Air conditioning system oil

180 m

VQ40DE Engine Capacity (Approximate)

Description Metric

US measure

Imp measure

21 1/8 gal

17 5/8 gal

With oil filter change

5.1

5 3/8 qt

4 1/2 qt

Without oil filter change

4.8

5 1/8 qt

4 1/4 qt

6.3

6 5/8 qt

5 1/2 qt

10.2

2 3/4 gal

2 1/4 gal

10.3

10 7/8 qt

9 1/8 qt

2WD

3.98

8 3/8 pt

7 pt

4WD

4.18

8 7/8 pt

7 3/8 pt

C200

1.6

3 3/8 pt

2 7/8 pt

M226

2.01

4 1/4 pt

3 1/2 pt

TX15B

2.0

2 1/8 qt

1 3/4 qt

Front final drive oil

0.85

1 3/4 pt

1 1/2 pt

Power steering fluid (PSF)

1.0

2 1/8 pt

1 3/4 pt

Windshield washer fluid

4.5

1 1/4 gal

1 gal

1.54 ± 0.11 lb

6.1 fl oz

6.3 fl oz

Fuel Engine oil Drain and refill Dry engine (engine overhaul) Cooling system

With reservoir at MAX level

Automatic transmission fluid (ATF) Manual transmission fluid (MTF) (6M/T)

Rear final drive oil Transfer fluid

A/C system refrigerant A/C system oil

0.70 ± 0.05 kg 180 m

A GENERAL INFORMATION GI

SECTION

GENERAL INFORMATION

CONTENTS PRECAUTIONS .......................................................... 3 Description ............................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 General Precautions ................................................ 3 Precautions for Three Way Catalyst ......................... 5 Precautions for Fuel ................................................. 5 QR25DE MODELS ................................................ 5 VQ40DE MODELS ................................................ 5 Precautions for Multiport Fuel Injection System or Engine Control System ............................................ 5 Precautions for Hoses .............................................. 6 HOSE REMOVAL AND INSTALLATION ............... 6 HOSE CLAMPING ................................................ 6 Precautions for Engine Oils ...................................... 6 HEALTH PROTECTION PRECAUTIONS ............. 6 ENVIRONMENTAL PROTECTION PRECAUTIONS ................................................................... 7 Precautions for Air Conditioning ............................... 7 HOW TO USE THIS MANUAL ................................... 8 Description ............................................................... 8 Terms ....................................................................... 8 Units ......................................................................... 8 Contents ................................................................... 8 Relation between Illustrations and Descriptions ..... 9 Components ............................................................. 9 SYMBOLS ........................................................... 10 How to Follow Trouble Diagnoses .......................... 10 DESCRIPTION .....................................................11 HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES ............................................... 12 HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION ....................................... 12 KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES ............................... 14 How to Read Wiring Diagrams ............................... 16 CONNECTOR SYMBOLS ................................... 16 SAMPLE/WIRING DIAGRAM - EXAMPL - ......... 17

Revision: September 2005

DESCRIPTION .................................................... 18 Abbreviations .......................................................... 23 SERVICE INFORMATION FOR ELECTRICAL INCIDENT ......................................................................... 25 How to Check Terminal ........................................... 25 CONNECTOR AND TERMINAL PIN KIT ............ 25 HOW TO PROBE CONNECTORS ...................... 25 How to Perform Efficient Diagnosis for an Electrical Incident ................................................................... 28 WORK FLOW ...................................................... 28 INCIDENT SIMULATION TESTS ........................ 28 CIRCUIT INSPECTION ....................................... 31 Control Units and Electrical Parts ........................... 36 PRECAUTIONS .................................................. 36 CONSULT-II CHECKING SYSTEM .......................... 38 Description .............................................................. 38 Function and System Application ........................... 38 Nickel Metal Hydride Battery Replacement ............ 39 Checking Equipment .............................................. 39 CONSULT-II Start Procedure .................................. 39 CONSULT-II Data Link Connector (DLC) Circuit ... 41 LIFTING POINT ......................................................... 43 Pantograph Jack ..................................................... 43 Garage Jack and Safety Stand ............................... 43 2-Pole Lift ............................................................... 44 TOW TRUCK TOWING ............................................. 45 Tow Truck Towing ................................................... 45 2WD MODEL ....................................................... 45 4WD MODEL ....................................................... 46 Vehicle Recovery (Freeing a stuck vehicle) ............ 46 TIGHTENING TORQUE OF STANDARD BOLTS ... 47 Tightening Torque Table ......................................... 47 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ............................................................... 48 Recommended Chemical Products and Sealants... 48 IDENTIFICATION INFORMATION ............................ 49 Model Variation ....................................................... 49 Identification Number .............................................. 51 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT ................................................ 51

GI-1

2006 Frontier

ENGINE SERIAL NUMBER ................................ 52 TRANSFER SERIAL NUMBER ........................... 52 AUTOMATIC TRANSMISSION NUMBER ........... 52 MANUAL TRANSMISSION NUMBER ................. 53

Revision: September 2005

Dimensions .............................................................54 Wheels & Tires ........................................................54 TERMINOLOGY ........................................................55 SAE J1930 Terminology List ...................................55

GI-2

2006 Frontier

PRECAUTIONS PRECAUTIONS Description

PFP:00001

GI EAS001G7

Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section.

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

EAS001G8

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.

General Precautions ●

●

Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle.

Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting before working on the vehicle. These operations should be done on a level surface. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.

GI-3

SGI231

Revision: September 2005

EAS001G9

SGI285

●

2006 Frontier

PRECAUTIONS ●

●

Before starting repairs which do not require battery power: Turn off ignition switch. Disconnect the negative battery terminal. If the battery terminals are disconnected, recorded memory of radio and each control unit is erased.

SEF289H

●

● ● ●

● ● ● ●

●

To prevent serious burns: Avoid contact with hot metal parts. Do not remove the radiator cap when the engine is hot. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel spray and possibly a fire. Clean all disassembled parts in the designated liquid or solvent SGI233 prior to inspection or assembly. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. Replace inner and outer races of tapered roller bearings and needle bearings as a set. Arrange the disassembled parts in accordance with their assembled locations and sequence. Do not touch the terminals of electrical components which use microcomputers (such as ECM). Static electricity may damage internal electronic components. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. Use only the fluids and lubricants specified in this manual. Use approved bonding agent, sealants or their equivalents when required. Use hand tools, power tools (disassembly only) and recommended special tools where specified for safe and efficient service repairs. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.

PBIC0190E

●

Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint.

SGI234

Revision: September 2005

GI-4

2006 Frontier

PRECAUTIONS WARNING: To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness GI connectors which are related to the engine control system and TCM (transmission control module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections. B

Precautions for Three Way Catalyst

EAS001GA

If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions. ● Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. ● When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. ● Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the catalyst. Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst.

Precautions for Fuel

EAS001MP

QR25DE MODELS Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research octane number 91). E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) may only be used in vehicles specifically designed for E-85 fuel (i.e. Flexible Fuel Vehicles - FFV models). CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel (i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

VQ40DE MODELS Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research octane number 91). E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) may only be used in vehicles specifically designed for E-85 fuel (i.e. Flexible Fuel Vehicles - FFV models).

For improved vehicle performance, NISSAN/INFINITI recommend the use of unleaded premium gasoline with an octane rating of at least 91 AKI number (Research octane number 96).

CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85 fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel (i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity.

Precautions for Multiport Fuel Injection System or Engine Control System ●

●

EAS001GC

Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM: Turn ignition switch to “OFF” position. Disconnect negative battery terminal. Otherwise, there may be damage to ECM. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure. Be careful not to jar components such as ECM and mass air flow sensor. SGI787

Revision: September 2005

GI-5

2006 Frontier

PRECAUTIONS Precautions for Hoses

EAS001GD

HOSE REMOVAL AND INSTALLATION ●

To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver.

SMA019D

●

To reinstall the rubber hose securely, make sure of hose insertion length and clamp orientation. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.)

SMA020D

HOSE CLAMPING ●

If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position.

SMA021D

● ●

Discard old clamps; replace with new ones. After installing leaf spring clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around.

SMA022D

Precautions for Engine Oils

EAS001GE

Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.

HEALTH PROTECTION PRECAUTIONS ●

Avoid prolonged and repeated contact with oils, particularly used engine oils.

Revision: September 2005

GI-6

2006 Frontier

PRECAUTIONS ● ● ● ●

● ● ●

● ● ● ●

Wear protective clothing, including impervious gloves where practicable. GI Do not put oily rags in pockets. Avoid contaminating clothes, particularly underpants, with oil. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned reguB larly. First aid treatment should be obtained immediately for open cuts and wounds. Use barrier creams, applying them before each work period, to help the removal of oil from the skin. C Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin. D If skin disorders develop, obtain medical advice without delay. Where practical, degrease components prior to handling. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face E shields; in addition an eye wash facility should be provided.

ENVIRONMENTAL PROTECTION PRECAUTIONS Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal facilities. It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources. The regulations concerning pollution vary between regions.

Precautions for Air Conditioning

EAS001GF

Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to MTC-99, "HFC-134a (R-134a) Service Procedure" for specific instructions.

Revision: September 2005

GI-7

2006 Frontier

HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL Description

PFP:00008 EAS001GG

This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diagnoses”.

Terms ●

EAS001GH

The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information. Standard value: Tolerance at inspection and adjustment. Limit value: The maximum or minimum limit value that should not be exceeded at inspection and adjustment.

Units ●

EAS001GI

The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. “Example” Outer Socket Lock Nut

: 59 - 78 N-m (6.0 - 8.0 kg-m, 43 - 58 ft-lb)

Contents

EAS001GJ

●

ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and page you are searching for.

●

A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the first page of each section by matching it to the section's black tab. THE CONTENTS are listed on the first page of each section. THE TITLE is indicated on the upper portion of each page and shows the part or system. THE PAGE NUMBER of each section consists of two or three letters which designate the particular section and a number (e.g. “BR-5”). THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary.

● ● ●

●

Revision: September 2005

GI-8

2006 Frontier

HOW TO USE THIS MANUAL Relation between Illustrations and Descriptions

EAS001WS

The following sample explains the relationship between the part description in an illustration, the part name in the text and the service procedures.

SAIA0519E

Components â&#x2014;?

EAS001GK

THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG . Components shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration.

Revision: September 2005

GI-9

2006 Frontier

HOW TO USE THIS MANUAL

SFIA2959E

Union bolt

Copper washer

Brake hose

Cap

Bleed valve

Sliding pin bolt

Piston seal

Piston boot

Piston

10. Cylinder body

11.

Sliding pin

12. Torque member mounting bolt

13. Washer

14.

Sliding pin boot

15. Bushing

16. Torque member

17.

Inner shim cover

18. Inner shim

19. Inner pad

20.

Pad retainer

21. Pad wear sensor

22. Outer pad

23.

Outer shim

24. Outer shim cover

1: PBC (Poly Butyl Cuprysil) grease or silicone-based grease

2: Rubber grease

: Brake fluid

Refer to GI section for additional symbol definitions.

SYMBOLS

SAIA0749E

How to Follow Trouble Diagnoses

EAS001GL

NOTICE: Trouble diagnoses indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1. Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the “Work Flow”. 2. After repairs, re-check that the problem has been completely eliminated. Revision: September 2005

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HOW TO USE THIS MANUAL 3. 4.

5. 6. 7.

Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors. GI Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG B section for identification of harness connectors. When checking circuit continuity, ignition switch should be OFF. Before checking voltage at connectors, check battery voltage. C After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were. D

DESCRIPTION NOTICE: Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1. Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the “Work Flow”. 2. After repairs, re-check that the problem has been completely eliminated. 3. Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors. 4. Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identification of harness connectors. 5. When checking circuit continuity, ignition switch should be OFF. 6. Before checking voltage at connectors, check battery voltage. 7. After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were.

Revision: September 2005

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HOW TO USE THIS MANUAL HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES

SAIA0256E

1. 2.

Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups. Questions and required results Questions and required results are indicated in bold type in test group. The meaning of are as follows: a. Battery voltage → 11 - 14V or approximately 12V b. Voltage : Approximately 0V → Less than 1V

Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Refer to "Connector Symbols" in GI Section and "KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES" below. Action items Next action for each test group is indicated based on result of each question. Test group number is shown in the left upper portion of each test group.

HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION There are two types of harness wire color and connector number indication.

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HOW TO USE THIS MANUAL Type 1: Harness Wire Color And Connector Number Are Shown In Illustration ●

●

Letter designations next to test meter probe indicate harness wire color. Connector numbers in a single circle (e.g. M33) indicate harness connectors. Connector numbers in a double circle indicate component connectors.

G AGI070

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HOW TO USE THIS MANUAL Type 2: Harness Wire Color And Connector Number Are Shown In Text

SGI144A

KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES

SAIA0750E

Revision: September 2005

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HOW TO USE THIS MANUAL GI

SAIA0751E

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HOW TO USE THIS MANUAL How to Read Wiring Diagrams

EAS001GM

CONNECTOR SYMBOLS Most of connector symbols in wiring diagrams are shown from the terminal side. ● Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. ● Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. ● Certain systems and components, especially related to OBD, may use a new style slide-locking type harness connector. For description and how to disconnect, refer to PG-84, "HARNESS CONNECTOR" .

SGI364

●

Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams.

SGI363

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HOW TO USE THIS MANUAL SAMPLE/WIRING DIAGRAM - EXAMPL ●

For detail, refer to following “DESCRIPTION”.

SGI091A

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HOW TO USE THIS MANUAL Optional Splice

SGI942

DESCRIPTION Number

Item

Power condition

Fusible link

Fusible link/fuse location

Fuse

Current rating

Connectors

Description ●

This shows the condition when the system receives battery positive voltage (can be operated).

●

The double line shows that this is a fusible link.

●

The open circle shows current flow in, and the shaded circle shows current flow out.

●

This shows the location of the fusible link or fuse in the fusible link or fuse box. For arrangement, refer to PG section, POWER SUPPLY ROUTING.

●

The single line shows that this is a fuse.

●

The open circle shows current flow in, and the shaded circle shows current flow out.

●

This shows the current rating of the fusible link or fuse.

●

This shows that connector E3 is female and connector M1 is male.

●

The G/R wire is located in the 1A terminal of both connectors.

●

Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ connector. Refer to PG section, SMJ (SUPER MULTIPLE JUNCTION).

Optional splice

●

The open circle shows that the splice is optional depending on vehicle application.

Splice

●

The shaded circle shows that the splice is always on the vehicle.

Page crossing

●

This arrow shows that the circuit continues to an adjacent page.

●

The A will match with the A on the preceding or next page.

Common connector

●

The dotted lines between terminals show that these terminals are part of the same connector.

Option abbreviation

●

This shows that the circuit is optional depending on vehicle application.

Relay

●

This shows an internal representation of the relay. For details, refer to PG section, STANDARDIZED RELAY.

Connectors

●

This shows that the connector is connected to the body or a terminal with bolt or nut.

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HOW TO USE THIS MANUAL Number

Item

Description ●

Wire color

This shows a code for the color of the wire. BR = Brown OR or O = Orange P = Pink PU or V (Violet) = Purple GY or GR = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green

B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green

When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example: L/W = Blue with White Stripe 15

Option description

Switch

Assembly parts

Cell code

●

This shows a description of the option abbreviation used on the page.

●

This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. Continuity exists between terminals 1 and 3 when the switch is in the B position.

●

Connector terminal in component shows that it is a harness incorporated assembly.

●

This identifies each page of the wiring diagram by section, system and wiring diagram page number.

●

Arrow indicates electric current flow, especially where the direction of standard flow (vertically downward or horizontally from left to right) is difficult to follow.

●

A double arrow “ cuit operation.

●

This shows that the system branches to another system identified by cell code (section and system).

●

This arrow shows that the circuit continues to another page identified by cell code.

Current flow arrow

System branch

” shows that current can flow in either direction depending on cir-

Page crossing

●

The C will match with the C on another page within the system other than the next or preceding pages.

Shielded line

●

The line enclosed by broken line circle shows shield wire.

Component box in wave line

●

This shows that another part of the component is also shown on another page (indicated by wave line) within the system.

Component name

●

This shows the name of a component.

●

This shows the connector number.

●

The letter shows which harness the connector is located in.

●

Example: M : main harness. For detail and to locate the connector, refer to PG section "Main Harness", “Harness Layout”. A coordinate grid is included for complex harnesses to aid in locating connectors.

●

The line spliced and grounded under wire color shows that ground line is spliced at the grounded connector.

●

This shows the ground connection. For detailed ground distribution information, refer to "Ground Distribution" in PG section.

●

This area shows the connector faces of the components in the wiring diagram on the page.

●

Connectors enclosed in broken line show that these connectors belong to the same component.

●

This shows a code for the color of the connector. For code meaning, refer to wire color codes, Number 14 of this chart.

●

This shows the arrangement of fusible link(s) and fuse(s), used for connector views of "POWER SUPPLY ROUTING" in PG section. The open square shows current flow in, and the shaded square shows current flow out.

●

This shows that more information on the Super Multiple Junction (SMJ) and Joint Connectors (J/C) exists on the PG section. Refer to "Reference Area" for details.

Connector number

Ground (GND)

Connector views

Common component

Connector color

Fusible link and fuse box

Reference area

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HOW TO USE THIS MANUAL Harness Indication ●

●

Letter designations next to test meter probe indicate harness (connector) wire color. Connector numbers in a single circle M33 indicate harness connectors.

AGI070

Component Indication Connector numbers in a double circle F211 indicate component connectors.

Switch Positions Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. A vehicle is in the “normal” condition when: ● ignition switch is “OFF”, ● doors, hood and trunk lid/back door are closed, ● pedals are not depressed, and ● parking brake is released.

SGI860

Detectable Lines and Non-Detectable Lines In some wiring diagrams, two kinds of lines, representing wires, with different weight are used.

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HOW TO USE THIS MANUAL ●

●

A line with regular weight (wider line) represents a “detectable line for DTC (Diagnostic Trouble Code)”. A “detectable line for DTC” is a circuit in which ECM can detect its malfunctions with the on board diagnostic system. A line with less weight (thinner line) represents a “non-detectable line for DTC”. A “non-detectable line for DTC” is a circuit in which ECM cannot detect its malfunctions with the on board diagnostic system.

G SGI862-B

Multiple Switch H

The continuity of multiple switch is described in two ways as shown below. ● The switch chart is used in schematic diagrams.

Revision: September 2005

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HOW TO USE THIS MANUAL â&#x2014;?

The switch diagram is used in wiring diagrams.

SGI875

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HOW TO USE THIS MANUAL Reference Area The Reference Area of the wiring diagram contains references to additional electrical reference pages at the GI end of the manual. If connector numbers and titles are shown in the Reference Area of the wiring diagram, these connector symbols are not shown in the Connector Area. B

SGI092A

Abbreviations

EAS001GN

The following ABBREVIATIONS are used: ABBREVIATION

DESCRIPTION

A/C

Air Conditioner

A/T

Automatic Transaxle/Transmission

ATF

Automatic Transmission Fluid

Drive range 1st gear

Drive range 2nd gear

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HOW TO USE THIS MANUAL ABBREVIATION

DESCRIPTION

Drive range 3rd gear

Drive range 4th gear

FR, RR

Front, Rear

LH, RH

Left-Hand, Right-Hand

M/T

Manual Transaxle/Transmission

Overdrive

P/S

Power Steering

SAE

Society of Automotive Engineers, Inc.

SDS

Service Data and Specifications

SST

Special Service Tools

2WD

2-Wheel Drive

2nd range 2nd gear

2nd range 1st gear

1st range 2nd gear

1st range 1st gear

Revision: September 2005

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT SERVICE INFORMATION FOR ELECTRICAL INCIDENT How to Check Terminal

PFP:00000

GI EAS001GO

CONNECTOR AND TERMINAL PIN KIT Use the connector and terminal pin kits listed below when replacing connectors or terminals. The connector and terminal pin kits contain some of the most commonly used NISSAN/INFINITI connectors and terminals. For detailed connector and terminal pin replacement procedures, refer to the latest NISSAN/ INFINITI CONNECTOR AND TERMINAL PIN SERVICE MANUAL.

Tool number (Kent-Moore No.) Tool name (J38751-95NI) Connector and terminal pin kit (NISSAN) (J38751-95INF) Connector and terminal pin kit (INFINITI) (J42992-98KIT) OBD and terminal repair kit (J42992-2000UPD) OBD-II Connector Kit Update

Description

G WAIA0004E

WAIA0005E

HOW TO PROBE CONNECTORS Connector damage and an intermittent connection can result from improperly probing of the connector during circuit checks. The probe of a digital multimeter (DMM) may not correctly fit the connector cavity. To correctly probe the connector, follow the procedures below using a “T” pin. For the best contact grasp the “T” pin using an alligator clip.

Probing from Harness Side Standard type (not waterproof type) connector should be probed from harness side with “T” pin. ● If the connector has a rear cover such as a ECM connector, remove the rear cover before probing the terminal. ● Do not probe waterproof connector from harness side. Damage to the seal between wire and connector may result.

SGI841

Probing from Terminal Side FEMALE TERMINAL ● There is a small notch above each female terminal. Probe each terminal with the “T” pin through the notch. Do not insert any object other than the same type male terminal into female terminal.

SEL265V

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT ●

Some connectors do not have a notch above each terminal. To probe each terminal, remove the connector retainer to make contact space for probing.

SEL266V

MALE TERMINAL Carefully probe the contact surface of each terminal using a “T” pin. Do not bend terminal.

SEL267V

How to Check Enlarged Contact Spring of Terminal An enlarged contact spring of a terminal may create intermittent signals in the circuit. If the intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact spring of female terminal. 1. Assemble a male terminal and approx. 10 cm (3.9 in) of wire. Use a male terminal which matches the female terminal. 2. Disconnect the suspected faulty connector and hold it terminal side up.

SEL270V

While holding the wire of the male terminal, try to insert the male terminal into the female terminal. Do not force the male terminal into the female terminal with your hands.

SEL271V

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT 4.

While moving the connector, check whether the male terminal can be easily inserted or not.

C SEL272V

D ●

If the male terminal can be easily inserted into the female terminal, replace the female terminal. E

G SEL273V

Waterproof Connector Inspection

If water enters the connector, it can short interior circuits. This may lead to intermittent problems. Check the following items to maintain the original waterproof characteristics. I

RUBBER SEAL INSPECTION ● Most waterproof connectors are provided with a rubber seal between the male and female connectors. If the seal is missing, the waterproof performance may not meet specifications. ● The rubber seal may come off when connectors are disconnected. Whenever connectors are reconnected, make sure the rubber seal is properly installed on either side of male or female connector.

L SEL275V

WIRE SEAL INSPECTION The wire seal must be installed on the wire insertion area of a waterproof connector. Be sure that the seal is installed properly.

Terminal Lock Inspection Check for unlocked terminals by pulling wire at the end of connector. An unlocked terminal may create intermittent signals in the circuit.

SEL330V

Revision: September 2005

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT How to Perform Efficient Diagnosis for an Electrical Incident

EAS001GP

WORK FLOW

SGI838

STEP

DESCRIPTION Get detailed information about the conditions and the environment when the incident occurred. The following are key pieces of information required to make a good analysis:

STEP 1

STEP 2

WHAT

Vehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio).

WHEN

Date, Time of Day, Weather Conditions, Frequency.

WHERE

Road Conditions, Altitude and Traffic Situation.

HOW

System Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories have been installed.

Operate the system, road test if necessary. Verify the parameter of the incident. If the problem cannot be duplicated, refer to “Incident Simulation Tests”. Get the proper diagnosis materials together including:

STEP 3

●

Power Supply Routing

●

System Operation Descriptions

●

Applicable Service Manual Sections

●

Check for any Service Bulletins

Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments. STEP 4

Inspect the system for mechanical binding, loose connectors or wiring damage. Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Layouts.

STEP 5

Repair or replace the incident circuit or component.

STEP 6

Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inadvertently created a new incident during your diagnosis or repair steps.

INCIDENT SIMULATION TESTS Introduction Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The following section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident. The section is broken into the six following topics: ● Vehicle vibration ● Heat sensitive Revision: September 2005

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT Freezing GI ● Water intrusion ● Electrical load ● Cold or hot start up B Get a thorough description of the incident from the customer. It is important for simulating the conditions of the problem. ●

Vehicle Vibration

The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration. CONNECTORS & HARNESS Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each connector and harness while monitoring the system for the incident you are trying to duplicate. This test may indicate a loose or poor electrical connection. HINT Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system. SENSORS & RELAYS Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a loose or poorly mounted sensor or relay.

SGI839

ENGINE COMPARTMENT There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: ● Connectors not fully seated. ● Wiring harness not long enough and is being stressed due to engine vibrations or rocking. ● Wires laying across brackets or moving components. ● Loose, dirty or corroded ground wires. ● Wires routed too close to hot components. To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground Inspection described later.) First check that the system is properly grounded. Then check for loose connection by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the wiring for continuity. BEHIND THE INSTRUMENT PANEL An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle vibration can aggravate a harness which is routed along a bracket or near a screw. UNDER SEATING AREAS Revision: September 2005

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2006 Frontier

SERVICE INFORMATION FOR ELECTRICAL INCIDENT An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides) during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or pinching.

Heat Sensitive The customer's concern may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a heat sensitive condition. To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. Do not heat components above 60Â°C (140Â°F). If incident occurs while heating the unit, either replace or properly insulate the component.

SGI842

Freezing The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system. There are two methods to check for this. The first is to arrange for the owner to leave his car overnight. Make sure it will get cold enough to demonstrate his complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component.

SGI843

Water Intrusion The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash. Do not spray water directly on any electrical components.

SGI844

Electrical Load The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on.

SGI845

Cold or Hot Start Up On some occasions an electrical incident may occur only when the car is started cold, or it may occur when the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to make a proper diagnosis. Revision: September 2005

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2006 Frontier

SERVICE INFORMATION FOR ELECTRICAL INCIDENT CIRCUIT INSPECTION Introduction

In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation. Then you will be able to use the appropriate equipment and follow the correct test procedure. You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this. OPEN

A circuit is open when there is no continuity through a section of the circuit.

There are two types of shorts. SHORT

●

SHORT CIRCUIT

When a circuit contacts another circuit and causes the normal resistance to change.

●

SHORT TO GROUND

When a circuit contacts a ground source and grounds the circuit.

NOTE: Refer to “How to Check Terminal” to probe or check terminal.

Testing for “Opens” in the Circuit Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system.

J SGI846-A

CONTINUITY CHECK METHOD The continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistance function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Make sure to always start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits, please refer to the previous schematic. ● Disconnect the battery negative cable. ● Start at one end of the circuit and work your way to the other end. (At the fuse block in this example) ● Connect one probe of the DMM to the fuse block terminal on the load side. ● Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point A) ● Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B) ● Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C) Any circuit can be diagnosed using the approach in the previous example. VOLTAGE CHECK METHOD To help in understanding the diagnosis of open circuits please refer to the previous schematic. In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function. Revision: September 2005

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT Connect one probe of the DMM to a known good ground. ● Begin probing at one end of the circuit and work your way to the other end. ● With SW1 open, probe at SW1 to check for voltage. voltage; open is further down the circuit than SW1. no voltage; open is between fuse block and SW1 (point A). ● Close SW1 and probe at relay. voltage; open is further down the circuit than the relay. no voltage; open is between SW1 and relay (point B). ● Close the relay and probe at the solenoid. voltage; open is further down the circuit than the solenoid. no voltage; open is between relay and solenoid (point C). Any powered circuit can be diagnosed using the approach in the previous example. ●

Testing for “Shorts” in the Circuit To simplify the discussion of shorts in the system, please refer to the following schematic.

SGI847-A

RESISTANCE CHECK METHOD ● Disconnect the battery negative cable and remove the blown fuse. ● Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. ● Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known good ground. ● With SW1 open, check for continuity. continuity; short is between fuse terminal and SW1 (point A). no continuity; short is further down the circuit than SW1. ● Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between SW1 and the relay (point B). no continuity; short is further down the circuit than the relay. ● Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between relay and solenoid (point C). no continuity; check solenoid, retrace steps. VOLTAGE CHECK METHOD ● Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. ● Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground). ● With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage; short is between fuse block and SW1 (point A). no voltage; short is further down the circuit than SW1. ● With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check for voltage. voltage; short is between SW1 and the relay (point B). Revision: September 2005

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SERVICE INFORMATION FOR ELECTRICAL INCIDENT no voltage; short is further down the circuit than the relay. GI ● With SW1 closed, relay contacts jumped with fused jumper wire check for voltage. voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage; retrace steps and check power to fuse block. B Ground Inspection Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. When inspecting a ground connection follow these rules: ● Remove the ground bolt or screw. ● Inspect all mating surfaces for tarnish, dirt, rust, etc. ● Clean as required to assure good contact. ● Reinstall bolt or screw securely. ● Inspect for “add-on” accessories which may be interfering with the ground circuit. ● If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation. For detailed ground distribution information, refer to “Ground Distribution” in PG section.

M SGI853

Voltage Drop Tests Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation. Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able to carry the current. The single strand will have a high resistance to the current. This will be picked up as a slight voltage drop. Unwanted resistance can be caused by many situations as follows: ● Undersized wiring (single strand example) ● Corrosion on switch contacts ● Loose wire connections or splices. If repairs are needed always use wire that is of the same or larger gauge. MEASURING VOLTAGE DROP — ACCUMULATED METHOD Revision: September 2005

GI-33

2006 Frontier

SERVICE INFORMATION FOR ELECTRICAL INCIDENT Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the DMM should be closer to power and the negative lead closer to ground. ● Operate the circuit. ● The DMM will indicate how many volts are being used to “push” current through that part of the circuit. Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb. ●

SGI974

MEASURING VOLTAGE DROP — STEP-BY-STEP The step-by-step method is most useful for isolating excessive drops in low voltage systems (such as those in “Computer Controlled Systems”). Circuits in the “Computer Controlled System” operate on very low amperage. The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the system. Such resistance variation may be caused by poor connection, improper installation, improper wire gauge or corrosion. The step by step voltage drop test can identify a component or wire with too much resistance.

SAIA0258E

Revision: September 2005

GI-34

2006 Frontier

SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Unit Circuit Test GI

System Description:When the switch is ON, the control unit lights up the lamp.

D MGI034A

INPUT-OUTPUT VOLTAGE CHART Pin No. 1

Item Switch

Lamp

Voltage value [V]

Condition

In case of high resistance such as single strand [V] *

Switch ON

Battery voltage

Lower than battery voltage Approx. 8 (Example)

Switch OFF

Approx. 0

Switch ON

Battery voltage

Approx. 0 (Inoperative lamp)

Switch OFF

Approx. 0

The voltage value is based on the body ground. *:If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the lamp.

MGI035A

INPUT-OUTPUT VOLTAGE CHART Pin No.

Item

Lamp

Switch

Condition

Voltage value [V]

In case of high resistance such as single strand [V] *

Switch ON

Approx. 0

Battery voltage (Inoperative lamp)

Switch OFF

Battery voltage

Switch ON

Approx. 0

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

The voltage value is based on the body ground. *:If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp.

Revision: September 2005

GI-35

2006 Frontier

SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Units and Electrical Parts

EAS001GQ

PRECAUTIONS ● ● ●

● ●

Never reverse polarity of battery terminals. Install only parts specified for a vehicle. Before replacing the control unit, check the input and output and functions of the component parts. Do not apply excessive force when disconnecting a connector. If a connector is installed by tightening bolts, loosen bolt mounting it, then take it out by hand.

SAIA0251E

●

Before installing a connector, make sure the terminal is not bent or damaged, and then correctly connect it. When installing a connector by tightening bolts, fix it by tightening the mounting bolt until the painted projection of the connector becomes even with the surface.

SAIA0252E

●

For removal of the lever type connector, pull the lever up to the direction pointed to by the arrow A in the figure, and then remove the connector.

SAIA0253E

●

For installation of the lever type connector, pull down the lever to the direction pointed by the arrow B in the figure, and then push the connector until a clicking noise is heard.

SAIA0254E

Revision: September 2005

GI-36

2006 Frontier

SERVICE INFORMATION FOR ELECTRICAL INCIDENT ●

●

● ● ●

Do not apply excessive shock to the control unit by dropping or hitting it. Be careful to prevent condensation in the control unit due to rapid temperature changes and do not let water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle. Be careful not to let oil to get on the control unit connector. Avoid cleaning the control unit with volatile oil. Do not disassemble the control unit, and do not remove the upper and lower covers.

C SAIA0255E

D ●

●

When using a DMM, be careful not to let test probes get close to each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiting. When checking input and output signals of the control unit, use the specified check adapter.

SEF348N

Revision: September 2005

GI-37

2006 Frontier

CONSULT-II CHECKING SYSTEM CONSULT-II CHECKING SYSTEM Description ●

●

PFP:00000 EAS001X1

CONSULT-II is a hand-held type tester. When it is connected with a diagnostic connector equipped on the vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various kinds of diagnostic tests. Refer to “CONSULT Operator's Manual” for more information.

Function and System Application

Function

ENGINE

A/T

ABS

AIR BAG

IPDM E/R

BCM

METER

ALL MODE AWD/4WD*1

DIFF LOCK*1

NVIS (NATS)*2

NVIS (NATS BCM OR S/ENT)*2

EAS001X2

Work support

This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-II.

Self-diagnostic

Self-diagnostic can be performed quickly.

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

Trouble diagnostic record

Current self-diagnostic results and all trouble diagnostic records previously stored can be read.

Data monitor

Input/Output data in the ECM can be read.

Data monitor (spec)

Data monitor specification can be read.

CAN diagnosis support monitor

The communication condition of CAN communication line can be read.

Active test

Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECMs and also shifts some parameters in a specified range.

Function test

This mode can show results of self-diagnosis of ECU with either “OK” or “NG”. For engines, more practical tests regarding sensors/switches and/or actuators are available.

DTC & SRT confirmation

The results of SRT (System Readiness Test) and the selfdiagnosis status/result can be confirmed.

DTC work support

The operating condition to confirm Diagnosis Trouble Codes can be selected.

ECM/ECU part number

ECM/ECU part number can be read.

ECU discriminated No.

Classification number of a replacement ECU can be read to prevent an incorrect ECU from being installed.

Passenger Airbag

Displays the STATUS (readiness) of the front passenger air bag.

Configuration

Sets control module parameters to match vehicle options.

PIN read*3

This mode shows the BCM-specific 5-digit code.

Control unit

All registered ignition key IDs in NATS components can be initialized and new IDs can be registered.

Diagnostic test mode

initialization*3

x: Applicable. *1: If equipped. *2: NVIS (NATS) [NISSAN Vehicle Immobilizer System (Nissan Anti-Theft System)].

Revision: September 2005

GI-38

2006 Frontier

CONSULT-II CHECKING SYSTEM *3: This system is shown with NVIS (NATS) using program card AEN04A or later.

Nickel Metal Hydride Battery Replacement

EAS001X3

CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following: WARNING: Replace the nickel metal hydride battery with Genuine CONSULT-II battery only. Use of another battery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if mistreated. Do not recharge, disassemble or dispose of in fire. Keep the battery out of reach of children and discard used battery conforming to the local regulations.

Checking Equipment

EAS001X4

When ordering the below equipment, contact your NISSAN distributor. Tool name

Description

NISSAN CONSULT-II (J-44200)

1. CONSULT-II unit (Tester internal soft: Resident version 3.4.0) and accessories. 2. Program cards UED05B and AEN04A-1 (For NATS) or later. To confirm the best combination of these softwares, refer to CONSULT-II Operation Manual.

3. CONSULT-II CONVERTER.

4. "CONSULT-II Pigtail" cable.

SAIA0363E

CAUTION: ● Previous CONSULT-II “I” and “Y” DLC-I and DLC-II cables should NOT be used anymore because their DDL connector pins can be damaged during cable swapping. ● If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in selfdiagnosis depending on control unit which carries out CAN communication. ● If CONSULT-II CONVERTER is not connected with CONSULT-II, the vehicle enters “FAIL SAFE MODE” which will “LIGHT UP the HEAD LIGHT” and /or “COOLING FAN ROTATING” when CONSULT-II is started. NOTE: ● The CONSULT-II must be used in conjunction with a program card. CONSULT-II does not require loading (Initialization) procedure. ● Be sure the CONSULT-II is turned OFF before installing or removing a program card.

CONSULT-II Start Procedure

EAS001X5

NOTE: Turning ignition switch off when performing CAN diagnosis could cause CAN memory to be erased. 1. Connect CONSULT-II and CONSULT-II CONVERTER to the data link connector.

PAIA0070E

Revision: September 2005

GI-39

2006 Frontier

CONSULT-II CHECKING SYSTEM 2. 3.

If necessary, turn on the ignition switch. Touch “START (NISSAN BASED VHCL)” or “System Shortcut" eg: ENGINE) on the screen.

BCIA0029E

Revision: September 2005

GI-40

2006 Frontier

CONSULT-II CHECKING SYSTEM CONSULT-II Data Link Connector (DLC) Circuit

EAS001X6

WAWA0004E

Revision: September 2005

GI-41

2006 Frontier

CONSULT-II CHECKING SYSTEM Symptom CONSULT-II cannot access any system.

CONSULT-II cannot access individual system. (Other systems can be accessed.)

Check item ●

CONSULT-II DLC power supply circuit (Terminal 8) and ground circuit (Terminal 4). For detailed circuit, refer to EC-613, "Wiring Diagram" (QR25DE) or EC-1297, "Wiring Diagram" (VQ40DE).

●

CONSULT-II DLC cable and CONSULT-II CONVERTER.

●

CONSULT-II program card (Check the appropriate CONSULT-II program card for the system. Refer to GI-39, "Checking Equipment" .

●

Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring diagram for each system.)

●

Open or short circuit between the system and CONSULT-II DLC (For detailed circuit, refer to wiring diagram for each system.)

●

Open or short circuit in CAN or K communication line. Refer to LAN-3, "Precautions When Using CONSULT-II" .

NOTE: The actual DDL1 circuits (CAN lines) from DLC pins 6 and 14 as well as the DDL2 circuit (K-line) from DLC pin 7 are connected to more than one system. A short in a DDL circuit connected to a control unit in one system may affect CONSULT-II access to other systems.

Revision: September 2005

GI-42

2006 Frontier

LIFTING POINT LIFTING POINT Pantograph Jack

PFP:00000

GI EAS001GX

H LAIA0052E

Garage Jack and Safety Stand

EAS001GY

CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat.

WAIA0042E

Revision: September 2005

GI-43

2006 Frontier

LIFTING POINT 2-Pole Lift

EAS001GZ

WARNING: â&#x2014;? When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. â&#x2014;? When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, or fuel lines.

WAIA0043E

Revision: September 2005

GI-44

2006 Frontier

TOW TRUCK TOWING TOW TRUCK TOWING Tow Truck Towing

PFP:00000

GI EAS001H0

WARNING: ● Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle. ● Place wheel chocks at both front and back of the wheels on the ground. CAUTION: ● All applicable State or Provincial (in Canada) laws and local laws regarding the towing operation must be obeyed. ● It is necessary to use proper towing equipment to avoid possible damage during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. ● Always attach safety chains before towing. ● When towing, make sure that the transmission, steering system and powertrain are in good order. If any unit is damaged, dollies must be used. ● Never tow an automatic transmission model from the rear (i.e., backward) with four wheels on the ground as this may cause serious and expensive damage to the transmission.

H AGI077

2WD MODEL NISSAN does not recommend towing automatic transmission equipped vehicles with the drive wheels on the ground. CAUTION: ● When towing with the front wheels on the ground: Turn the ignition key to the OFF position and move the transmission selector lever to N (neutral) position, turn the ignition key to OFF position and secure the steering wheel in a straight ahead position with a rope or similar device. Never place the ignition key in the LOCK position. This will result in damage to the steering lock mechanism.

SGI976

Revision: September 2005

GI-45

2006 Frontier

TOW TRUCK TOWING 4WD MODEL NISSAN recommends that towing dollies be used when towing 4WD equipped vehicles or place the vehicle on a flat bed truck. CAUTION: ● Never tow 4WD models with any of the wheels on the ground as this may cause serious and expensive damage to the transfer case and transmission.

SGI973

Towing Point CAUTION: Never tow the vehicle using only the towing points. To avoid damaging the vehicle body, use proper towing equipment when towing.

LAIA0053E

Vehicle Recovery (Freeing a stuck vehicle) ● ●

●

EAS001H1

Tow chains or cables must be attached only to the main structural members of the vehicle. Pulling devices should be routed so they do not touch any part of the suspension, steering, brake or cooling systems Always pull the cable straight out from the front or rear of the vehicle. Never pull the vehicle at a sideways angle. Pulling devices such as ropes or canvas straps are not recommended for use for vehicle towing or recovery.

Revision: September 2005

GI-46

2006 Frontier

TIGHTENING TORQUE OF STANDARD BOLTS TIGHTENING TORQUE OF STANDARD BOLTS Tightening Torque Table Grade

Bolt size

M6 M8

M10

M12

6.0 8.0

10.0

12.0

GI EAS001H2

Tightening torque (Without lubricant) Pitch mm

Hexagon head bolt N·m

kg-m

Hexagon flange bolt

ft-lb

in-lb

N·m

kg-m

ft-lb

in-lb

1.0

5.1

0.52

3.8

45.1

6.1

0.62

4.5

53.8

1.25

1.3

—

1.5

—

1.0

1.3

—

1.6

—

1.5

2.5

—

3.0

—

1.25

2.6

—

3.1

—

1.75

4.3

—

5.2

—

1.25

4.7

—

5.7

—

M14

14.0

1.5

7.5

—

9.0

—

6.0

1.0

8.4

0.86

6.2

74.6

1.0

8.0

1.25

2.1

—

2.5

—

1.0

2.2

—

2.7

—

1.5

4.2

—

4.9

—

1.25

4.4

—

5.2

—

1.75

7.2

—

8.6

—

1.25

7.9

—

9.4

—

M10

M12

Bolt diameter * mm

PFP:00000

10.0

12.0

M14

14.0

1.5

127

13.0

—

147

15.0

108

—

6.0

1.0

1.2

—

1.5

—

8.0

1.25

3.0

—

3.6

—

1.0

3.2

—

3.8

—

1.5

6.0

—

7.1

—

1.25

6.3

—

7.5

—

1.75

10.0

—

118

12.0

—

1.25

108

11.0

—

137

14.0

101

—

1.5

177

18.0

130

—

206

21.0

152

—

M10

M12 M14

10.0

12.0 14.0

*: Nominal diameter 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head.

MGI044A

Revision: September 2005

GI-47

2006 Frontier

RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS Recommended Chemical Products and Sealants

PFP:00000 EAS001H3

Refer to the following chart for help in selecting the appropriate chemical product or sealant. Product Description

Purpose

999MP-AM000P

99998-50505

Permatex 81844

Anaerobic Liquid Gasket

For metal-to-metal flange sealing. Can fill a 0.38 mm (0.015 inch) gap and provide instant sealing for most powertrain applications.

999MP-AM001P

99998-50503

Permatex 51813 and 51817

999MP-AM002P

Permatex 56521

99998-50506 (Ultra Grey)

Permatex Ultra Grey 82194; Three Bond 1207,1215, 1216, 1217F and 1217G; Nissan RTV Part No. 999MP-A7007

High Performance Thread Sealant

Provides instant sealing on any threaded straight or parallel threaded fitting. (Thread sealant only, no locking ability.) Do not use on plastic.

999MP-AM003P (Ultra Grey)

Silicone RTV Gasket Maker for Maxima/ Quest 5-speed automatic transmission (RE5F22A)

Aftermarket Crossreference Part Nos.

Used to permanently remount rear view mirrors to windows.

Gasket Maker

Nissan Canada Part No. (Canada)

Rear View Mirror Adhesive

●

Nissan North America Part No. (USA)

High Temperature, High Strength Thread Locking Sealant (Red)

Medium Strength Thread Locking Sealant (Blue)

Revision: September 2005

Threadlocker

Threadlocker (service tool removable)

–

999MP-AM004P

999MP-AM005P

GI-48

–

Three Bond 1281B or exact equivalent in its quality

999MP-AM004P

Permatex 27200; Three Bond 1360, 1360N, 1305 N&P, 1307N, 1335, 1335B, 1363B, 1377C, 1386B, D&E and 1388

999MP-AM005P

Permatex 24200, 24206, 24240, 24283 and 09178; Three Bond 1322, 1322N, 1324 D&N, 1333D, 1361C, 1364D, 1370C and 1374

2006 Frontier

IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION Model Variation Position 1

Character B

PFP:00010

GI EAS001H4

Qualifier Body type

Definition

B: King Cab C: Crew Cab

Engine

3 4

CK: VQ40DE

DB: QR25DE A

Axle

A: 2WD

N: 4WD 5

Drive

L: LH R: XE

Grade

T: SE V: LE

U: NISMO Off-Road F: 5-speed manual transmission 7

Transmission

N: 5-speed automatic transmission

Y: 6-speed manual transmission 8 9

H48

Model

H48 Frontier

Intake

E: EGI

Zone

N: Canada U: Federal

Equipment

N: Standard

Option Codes

14 15 16

XXXXX

17 18

Revision: September 2005

GI-49

2006 Frontier

IDENTIFICATION INFORMATION 2WD Model Body

Engine

Transmission

Destination

Grade

Model

BDBALRF-EUN

BDBALRN-EUN

BDBALRF-ENN

BDBALRN-ENN

BCKALTY-EUN

BCKALTN-EUN

RE5R05A Automatic

NISMO OffRoad

BCKALUN-EUN

RE5R05A Automatic

BCKALVN-EUN

FS6R31A Manual

BCKALTY-ENN

BCKALTN-ENN

RE5R05A Automatic

BCKALVN-ENN

FS6R31A Manual

CCKALTY-EUN

FS5R30A Manual RE5R05A Automatic QR25DE

U.S.A.

FS5R30A Manual RE5R05A Automatic

Canada

FS6R31A Manual RE5R05A Automatic

King Cab

U.S.A. VQ40DE

RE5R05A Automatic

Canada

RE5R05A Automatic

CCKALTN-EUN

NISMO OffRoad

CCKALUN-EUN

RE5R05E Automatic

CCKALVN-EUN

FS6R31E Manual

CCKALTY-ENN

CCKALTN-ENN

CCKALVN-ENN

Grade

Model

FS6R31A Manual

BCKNLTY-EUN

RE5R05A Automatic

BCKNLTN-EUN

NISMO OffRoad

BCKNLUY-EUN

RE5R05A Automatic

NISMO OffRoad

BCKNLUN-EUN

RE5R05A Automatic

BCKNLVN-EUN

FS6R31A Manual

BCKNLTY-ENN

RE5R05A Automatic

BCKNLTN-ENN

NISMO OffRoad

BCKNLUY-ENN

NISMO OffRoad

BCKNLUN-ENN

RE5R05A Automatic

BCKNLVN-ENN

FS6R31A Manual

CCKNLTY-EUN

RE5R05A Automatic

CCKNLTN-EUN

NISMO OffRoad

CCKNLUN-EUN

CCKNLVN-EUN

RE5R05A Automatic Crew Cab

VQ40DE

RE5R05A Automatic

U.S.A.

Canada

RE5R05A Automatic

4WD Model Body

Engine

Transmission

FS6R31A Manual

King Cab

VQ40DE

FS6R31A Manual

Destination

U.S.A.

Canada

RE5R05A Automatic

RE5R05A Automatic Crew Cab

VQ40DE

U.S.A.

RE5R05A Automatic FS6R31A Manual

CCKNLTY-ENN

RE5R05A Automatic

CCKNLTN-ENN

RE5R05A Automatic

NISMO OffRoad

CCKNLUN-ENN

RE5R05A Automatic

CCKNLVN-ENN

Canada

Revision: September 2005

GI-50

2006 Frontier

IDENTIFICATION INFORMATION Identification Number

EAS001H5

F WAIA0091E

Emission control information/ Vacuum hose diagram label

Vehicle identification number plate

Tire placard and F.M.V.S.S. certification label

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT Position

Character

Qualifier

H Definition

1 2

1N6

Manufacturer

1N6: USA produced multi-purpose vehicle

3 A: VQ40DE 4

Engine type

Vehicle line

D: NISSAN Frontier

Model change

(0-9)

Body type

B: QR25DE

6: King Cab 7: Crew Cab

U: 2WD, 4-wheel ABS, Class D 8

Gross vehicle weight rating

W: 4WD, 4-wheel ABS, Class D T: 2WD, 4-wheel ABS, Class C

Check digit

(0 to 9 or X) The code for the check digit is determined by a mathematical computation.

Model year

2006

Manufacturing plant

C: Smyrna, Tennessee

Vehicle serial number

Chassis number

12 13 14

XXXXX

15 16 17

Revision: September 2005

GI-51

2006 Frontier

IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER VQ40DE

LAIA0055E

QR25DE

PAIA0280E

TRANSFER SERIAL NUMBER

AGI108

AUTOMATIC TRANSMISSION NUMBER

PAIA0054E

Revision: September 2005

GI-52

2006 Frontier

IDENTIFICATION INFORMATION MANUAL TRANSMISSION NUMBER GI

C LAIA0059E

Revision: September 2005

GI-53

2006 Frontier

IDENTIFICATION INFORMATION Dimensions

EAS001H6

Unit: mm (in) Drive type

2WD

4WD

Overall length

5220 (205.5)

Overall width

1850 (72.8)

King Cab *1

Overall height

Crew Cab*1

Crew Cab*2

235/75R15

1745 (68.7)

—

265/70R16

1748 (68.8)

1758 (69.2)

NISMO Off-Road

265/75R16

1758 (69.2)

1770 (69.7)

265/65R17

1748 (68.8)

1758 (69.2)

265/70R16

1760 (69.3)

1775 (69.9)

NISMO Off-Road

265/75R16

1773 (69.8)

1780 (70.1)

265/65R17

1760 (69.3)

1775 (69.9)

265/70R16

1852 (72.9)

1864 (73.4)

NISMO Off-Road

265/75R16

1864 (72.6)

1879 (73.9)

265/65R17

18520 (72.9)

1864 (73.4)

Front tread width

1570 (61.8)

Rear tread width

1569 (61.8)

Wheelbase

3200 (125.8)

King Cab Minimum Running Ground Clearance (with standard tires) Crew Cab

235/75R15

222 (8.7)

—

265/70R16

222 (8.7)

225 (8.8)

NISMO Off-Road

265/75R16

233 (9.2)

237 (9.3)

265/65R17

222 (8.7)

225 (8.9)

265/70R16

219 (8.6)

224 (8.8)

NISMO Off-Road

265/75R16

231 (9.1)

236 (9.2)

265/65R17

219 (8.6)

225 (8.9)

*1: Without roof rack *2: With roof rack

Wheels & Tires Drive Type All

EAS001H7

Grade

Road wheel

Tire

Spare tire size

15 X 7J Styled Steel

P235/75R15

16 X 7J Styled Steel

P265/70R16

NISMO OffRoad

16 X 7J Aluminum Alloy

P265/75R16

17 X 7.5J Aluminum Alloy

P265/65R17

Revision: September 2005

GI-54

2006 Frontier

TERMINOLOGY TERMINOLOGY SAE J1930 Terminology List

PFP:00011

GI EAS001H8

All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new terms, new acronyms/abbreviations and old terms are listed in the following chart. NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Air cleaner

ACL

Air cleaner

Barometric pressure

BARO

***

Barometric pressure sensor-BCDD

BAROS-BCDD

BCDD

Camshaft position

CMP

***

Camshaft position sensor

CMPS

Crank angle sensor

Canister

***

Canister

Carburetor

CARB

Carburetor

Charge air cooler

CAC

Intercooler

Closed loop

Closed throttle position switch

CTP switch

Idle switch

Clutch pedal position switch

CPP switch

Clutch switch

Continuous fuel injection system

CFI system

***

Continuous trap oxidizer system

CTOX system

***

Crankshaft position

CKP

***

Crankshaft position sensor

CKPS

***

Data link connector

DLC

***

Data link connector for CONSULT-II

DLC for CONSULT-II

Diagnostic connector for CONSULT-II

Diagnostic test mode

DTM

Diagnostic mode

Diagnostic test mode selector

DTM selector

Diagnostic mode selector

Diagnostic test mode I

DTM I

Mode I

Diagnostic test mode II

DTM II

Mode II

Diagnostic trouble code

DTC

Malfunction code

Direct fuel injection system

DFI system

***

Distributor ignition system

DI system

Ignition timing control

Early fuel evaporation-mixture heater

EFE-mixture heater

Mixture heater

Early fuel evaporation system

EFE system

Mixture heater control

Electrically erasable programmable read only memory

EEPROM

***

Electronic ignition system

EI system

Ignition timing control

Engine control

***

Engine control module

ECM

ECCS control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

***

Engine speed

RPM

Engine speed

Erasable programmable read only memory

EPROM

***

Evaporative emission canister

EVAP canister

Canister

Evaporative emission system

EVAP system

Canister control solenoid valve

Exhaust gas recirculation valve

EGR valve

Revision: September 2005

GI-55

2006 Frontier

TERMINOLOGY NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Exhaust gas recirculation control-BPT valve

EGRC-BPT valve

BPT valve

Exhaust gas recirculation control-solenoid valve

EGRC-solenoid valve

EGR control solenoid valve

EGRT sensor

Exhaust gas temperature sensor

Flash electrically erasable programmable read only memory

FEEPROM

***

Flash erasable programmable read only memory

FEPROM

***

Flexible fuel sensor

FFS

***

Flexible fuel system

FF system

***

Fuel pressure regulator

***

Pressure regulator

Fuel pressure regulator control solenoid valve

***

PRVR control solenoid valve

Fuel trim

***

Heated Oxygen sensor

HO2S

Exhaust gas sensor

Idle air control system

IAC system

Idle speed control

Idle air control valve-air regulator

IACV-air regulator

Air regulator

Idle air control valve-auxiliary air control valve

IACV-AAC valve

Auxiliary air control (AAC) valve

Idle air control valve-FICD solenoid valve

IACV-FICD solenoid valve

FICD solenoid valve

Idle air control valve-idle up control solenoid valve

IACV-idle up control solenoid valve

Idle up control solenoid valve

Idle speed control-FI pot

ISC-FI pot

FI pot

Idle speed control system

ISC system

***

Ignition control

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

Air

Exhaust gas recirculation temperature sensor EGR temperature sensor

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

Detonation sensor

Malfunction indicator lamp

MIL

Check engine light

Manifold absolute pressure

MAP

***

Manifold absolute pressure sensor

MAPS

***

Manifold differential pressure

MDP

***

Manifold differential pressure sensor

MDPS

***

Manifold surface temperature

MST

***

Manifold surface temperature sensor

MSTS

***

Manifold vacuum zone

MVZ

***

Manifold vacuum zone sensor

MVZS

***

Mass air flow sensor

MAFS

Air flow meter

Mixture control solenoid valve

MC solenoid valve

Air-fuel ratio control solenoid valve

Multiport fuel injection System

MFI system

Fuel injection control

Revision: September 2005

GI-56

2006 Frontier

TERMINOLOGY NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Nonvolatile random access memory

NVRAM

***

On board diagnostic system

OBD system

Self-diagnosis

Open loop

Oxidation catalyst

Catalyst

Oxidation catalytic converter system

OC system

***

Oxygen sensor

O2S

Exhaust gas sensor

Park position switch

***

Park switch

Park/neutral position switch

PNP switch

Park/neutral switch Inhibitor switch Neutral position switch

Periodic trap oxidizer system

PTOX system

***

Positive crankcase ventilation

PCV

Positive crankcase ventilation

Positive crankcase ventilation valve

PCV valve

Powertrain control module

PCM

***

Programmable read only memory

PROM

***

Pulsed secondary air injection control solenoid valve

PAIRC solenoid valve

AIV control solenoid valve

Pulsed secondary air injection system

PAIR system

Air induction valve (AIV) control

Pulsed secondary air injection valve

PAIR valve

Air induction valve

Random access memory

RAM

***

Read only memory

ROM

***

Scan tool

***

Secondary air injection pump

AIR pump

***

Secondary air injection system

AIR system

***

Sequential multiport fuel injection system

SFI system

Sequential fuel injection

Service reminder indicator

SRI

***

Simultaneous multiport fuel injection system

***

Simultaneous fuel injection

Smoke puff limiter system

SPL system

***

Supercharger

***

Supercharger bypass

SCB

***

System readiness test

SRT

***

Thermal vacuum valve

TVV

Thermal vacuum valve

Three way catalyst

TWC

Catalyst

Three way catalytic converter system

TWC system

***

Three way + oxidation catalyst

TWC + OC

Catalyst

Three way + oxidation catalytic converter system

TWC + OC system

***

Throttle body

Throttle chamber SPI body

Throttle body fuel injection system

TBI system

Fuel injection control

Throttle position

Throttle position sensor

TPS

Throttle sensor

Throttle position switch

TP switch

Throttle switch

Torque converter clutch solenoid valve

TCC solenoid valve

Lock-up cancel solenoid Lock-up solenoid

Revision: September 2005

GI-57

2006 Frontier

TERMINOLOGY NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Transmission control module

TCM

A/T control unit

Turbocharger

Vehicle speed sensor

VSS

Vehicle speed sensor

Volume air flow sensor

VAFS

Air flow meter

Warm up oxidation catalyst

WU-OC

Catalyst

Warm up oxidation catalytic converter system

WU-OC system

***

Warm up three way catalyst

WU-TWC

Catalyst

Warm up three way catalytic converter system

WU-TWC system

***

Wide open throttle position switch

WOTP switch

Full switch

***: Not applicable

Revision: September 2005

GI-58

2006 Frontier

B ENGINE A

SECTION

ENGINE MECHANICAL

CONTENTS QR PRECAUTIONS .......................................................... 5 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 5 Precautions for Drain Engine Coolant and Engine Oil ............................................................................. 5 Precautions for Disconnecting Fuel Piping .............. 5 Precautions for Removal and Disassembly ............. 5 Precautions for Inspection, Repair and Replacement ......................................................................... 5 Precautions for Assembly and Installation ............... 5 Parts Requiring Angle Tightening ............................. 6 Precautions for Liquid Gasket .................................. 6 REMOVAL OF LIQUID GASKET SEALING .......... 6 LIQUID GASKET APPLICATION PROCEDURE..... 6 PREPARATION ........................................................... 8 Special Service Tools ............................................... 8 Commercial Service Tools ...................................... 10 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .............................................. 12 NVH Troubleshooting — Engine Noise .................. 12 Use the Chart Below to Help You Find the Cause of the Symptom. ..................................................... 13 DRIVE BELTS ........................................................... 14 Checking Drive Belt ................................................ 14 Tension Adjustment ................................................ 14 Removal and Installation ........................................ 14 REMOVAL ........................................................... 14 INSTALLATION ................................................... 15 Removal and Installation of Drive Belt Auto-Tensioner ..................................................................... 15 REMOVAL ........................................................... 15 INSTALLATION ................................................... 15 AIR CLEANER AND AIR DUCT ............................... 16 Removal and Installation ........................................ 16 REMOVAL ........................................................... 16 INSPECTION AFTER REMOVAL ....................... 16

Revision: September 2005

INSTALLATION ................................................... 16 Changing Air Cleaner Filter .................................... 17 REMOVAL ........................................................... 17 INSTALLATION ................................................... 17 INTAKE MANIFOLD ................................................. 18 Removal and Installation ........................................ 18 REMOVAL ........................................................... 18 INSTALLATION ................................................... 19 INSPECTION AFTER INSTALLATION ................ 20 EXHAUST MANIFOLD AND THREE WAY CATALYST .......................................................................... 21 Removal and Installation ........................................ 21 REMOVAL ........................................................... 21 INSPECTION AFTER REMOVAL ....................... 22 INSTALLATION ................................................... 22 OIL PAN .................................................................... 23 Removal and Installation ........................................ 23 REMOVAL ........................................................... 23 INSTALLATION ................................................... 24 INSPECTION AFTER INSTALLATION ................ 24 IGNITION COIL ......................................................... 26 Removal and Installation ........................................ 26 REMOVAL ........................................................... 26 INSTALLATION ................................................... 26 SPARK PLUG (PLATINUM-TIPPED TYPE) ............. 27 Changing Spark Plugs (Platinum - Tipped Type) ... 27 REMOVAL ........................................................... 27 INSPECTION AFTER REMOVAL ....................... 27 INSTALLATION ................................................... 28 FUEL INJECTOR AND FUEL TUBE ........................ 29 Removal and Installation ........................................ 29 REMOVAL ........................................................... 29 INSTALLATION ................................................... 31 INSPECTION AFTER INSTALLATION ................ 33 ROCKER COVER ..................................................... 34 Removal and Installation ........................................ 34 REMOVAL ........................................................... 34 INSTALLATION ................................................... 35 CAMSHAFT .............................................................. 36 Removal and Installation ........................................ 36

EM-1

2006 Frontier

REMOVAL ........................................................... 36 INSPECTION AFTER REMOVAL ........................ 38 INSTALLATION .................................................... 41 INSPECTION AFTER INSTALLATION ................ 44 Valve Clearance ...................................................... 45 INSPECTION ....................................................... 45 ADJUSTMENT .................................................... 46 TIMING CHAIN .......................................................... 48 Removal and Installation ........................................ 48 REMOVAL ........................................................... 49 INSPECTION AFTER REMOVAL ........................ 52 INSTALLATION .................................................... 52 INSPECTION AFTER INSTALLATION ................ 56 OIL SEAL .................................................................. 57 Removal and Installation of Valve Oil Seal ............. 57 REMOVAL ........................................................... 57 INSTALLATION .................................................... 57 Removal and Installation of Front Oil Seal ............. 57 REMOVAL ........................................................... 57 INSTALLATION .................................................... 58 Removal and Installation of Rear Oil Seal .............. 58 REMOVAL ........................................................... 58 INSTALLATION .................................................... 58 CYLINDER HEAD ..................................................... 60 On-Vehicle Service ................................................. 60 CHECKING COMPRESSION PRESSURE ......... 60 Removal and Installation ........................................ 61 REMOVAL ........................................................... 61 INSPECTION AFTER REMOVAL ........................ 62 INSTALLATION .................................................... 63 INSPECTION AFTER INSTALLATION ................ 63 Disassembly and Assembly .................................... 64 DISASSEMBLY ................................................... 64 ASSEMBLY ......................................................... 65 Inspection After Disassembly ................................. 67 VALVE DIMENSIONS .......................................... 67 VALVE GUIDE CLEARANCE .............................. 67 VALVE GUIDE REPLACEMENT ......................... 67 VALVE SEAT CONTACT ..................................... 69 VALVE SEAT REPLACEMENT ........................... 69 VALVE SPRING SQUARENESS ......................... 70 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ............................... 70 ENGINE ASSEMBLY ................................................ 71 Removal and Installation ........................................ 71 REMOVAL ........................................................... 72 INSTALLATION .................................................... 73 INSPECTION AFTER INSTALLATION ................ 73 CYLINDER BLOCK ................................................... 75 Disassembly and Assembly .................................... 75 DISASSEMBLY ................................................... 76 ASSEMBLY ......................................................... 80 How to Select Piston and Bearing .......................... 85 DESCRIPTION .................................................... 85 HOW TO SELECT PISTON ................................. 85 HOW TO SELECT CONNECTING ROD BEARING ...................................................................... 86

Revision: September 2005

HOW TO SELECT MAIN BEARING ....................88 Inspection After Disassembly ..................................92 CRANKSHAFT END PLAY ..................................92 CONNECTING ROD SIDE CLEARANCE ...........92 PISTON TO PISTON PIN OIL CLEARANCE .......92 PISTON RING SIDE CLEARANCE .....................93 PISTON RING END GAP ....................................93 CONNECTING ROD BEND AND TORSION .......94 CONNECTING ROD BIG END DIAMETER ........94 CONNECTING ROD BUSHING OIL CLEARANCE ...................................................................94 CYLINDER BLOCK DISTORTION ......................95 MAIN BEARING HOUSING INNER DIAMETER...96 PISTON TO CYLINDER BORE CLEARANCE ...96 CRANKSHAFT MAIN JOURNAL DIAMETER .....97 CRANKSHAFT PIN JOURNAL DIAMETER ........98 OUT-OF-ROUND AND TAPER OF CRANKSHAFT .................................................................98 CRANKSHAFT RUNOUT ....................................98 CONNECTING ROD BEARING OIL CLEARANCE ...................................................................98 MAIN BEARING OIL CLEARANCE .....................99 MAIN BEARING CRUSH HEIGHT .................... 100 CONNECTING ROD BEARING CRUSH HEIGHT ............................................................. 100 LOWER CYLINDER BLOCK MOUNTING BOLT OUTER DIAMETER ........................................... 100 CONNECTING ROD BOLT OUTER DIAMETER.100 FLYWHEEL DEFLECTION (M/T MODELS) ...... 101 MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS) ........................................................... 101 SERVICE DATA AND SPECIFICATIONS (SDS) .... 102 Standard and Limit ................................................ 102 GENERAL SPECIFICATIONS ........................... 102 DRIVE BELT ...................................................... 102 EXHAUST MANIFOLD AND THREE WAY CATALYST ASSEMBLY ............................................ 102 SPARK PLUG .................................................... 102 CYLINDER HEAD .............................................. 102 VALVE ................................................................ 103 CAMSHAFT AND CAMSHAFT BEARING ......... 107 CYLINDER BLOCK ............................................ 107 PISTON, PISTON RING AND PISTON PIN ...... 109 CONNECTING ROD .......................................... 110 CRANKSHAFT ................................................... 110 MAIN BEARING ................................................. 112 CONNECTING ROD BEARING ......................... 113

VQ PRECAUTIONS ....................................................... 114 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ............................................................... 114 Precautions for Drain Engine Coolant ................... 114 Precautions for Disconnecting Fuel Piping ........... 114 Precautions for Removal and Disassembly .......... 114 Precautions for Inspection, Repair and Replacement ...................................................................... 114

EM-2

2006 Frontier

Precautions for Assembly and Installation ............114 Parts Requiring Angle Tightening ..........................115 Precautions for Liquid Gasket ...............................115 REMOVAL OF LIQUID GASKET SEALING .......115 LIQUID GASKET APPLICATION PROCEDURE..115 PREPARATION ........................................................117 Special Service Tools ............................................117 Commercial Service Tools .....................................119 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................................ 121 NVH Troubleshooting â&#x20AC;&#x201D;Engine Noise ................. 121 Use the Chart Below to Help You Find the Cause of the Symptom .................................................... 122 ENGINE ROOM COVER ........................................ 123 Removal and Installation ...................................... 123 REMOVAL ......................................................... 123 INSTALLATION ................................................. 123 DRIVE BELTS ......................................................... 124 Checking Drive Belts ............................................ 124 Tension Adjustment .............................................. 124 Removal and Installation ...................................... 124 DRIVE BELT ..................................................... 124 INSTALLATION ................................................. 125 Drive Belt Auto-Tensioner and Idler Pulley ........... 125 REMOVAL ......................................................... 125 INSTALLATION ................................................. 125 AIR CLEANER AND AIR DUCT ............................. 126 Removal and Installation ...................................... 126 REMOVAL ......................................................... 126 INSPECTION AFTER REMOVAL ..................... 126 INSTALLATION ................................................. 126 Changing Air Cleaner Filter .................................. 126 REMOVAL ......................................................... 126 INSTALLATION ................................................. 126 INTAKE MANIFOLD COLLECTOR ........................ 127 Removal and Installation ...................................... 127 REMOVAL ......................................................... 128 INSTALLATION ................................................. 129 INTAKE MANIFOLD ............................................... 130 Removal and Installation ...................................... 130 REMOVAL ......................................................... 130 INSPECTION AFTER REMOVAL ..................... 130 INSTALLATION ................................................. 131 EXHAUST MANIFOLD AND THREE WAY CATALYST ....................................................................... 132 Removal and Installation ...................................... 132 REMOVAL (LEFT BANK) .................................. 132 INSPECTION AFTER REMOVAL ..................... 133 INSTALLATION (LEFT BANK) .......................... 134 REMOVAL (RIGHT BANK) ............................... 135 INSPECTION AFTER REMOVAL ..................... 135 INSTALLATION (RIGHT BANK) ........................ 136

Revision: September 2005

OIL PAN AND OIL STRAINER ............................... 137 Removal and Installation ...................................... 137 REMOVAL (LOWER) ......................................... 137 INSPECTION AFTER REMOVAL ..................... 138 INSTALLATION (LOWER) ................................. 138 INSPECTION AFTER INSTALLATION .............. 139 REMOVAL (UPPER) ......................................... 139 INSPECTION AFTER REMOVAL ..................... 140 INSTALLATION (UPPER) .................................. 140 INSPECTION AFTER INSTALLATION .............. 141 IGNITION COIL ....................................................... 142 Removal and Installation ...................................... 142 REMOVAL (LEFT BANK) .................................. 142 INSTALLATION (LEFT BANK) .......................... 142 REMOVAL (RIGHT BANK) ................................ 142 INSTALLATION (RIGHT BANK) ........................ 142 SPARK PLUG (PLATINUM-TIPPED TYPE) ........... 143 Changing Spark Plugs (Platinum - Tipped Type) . 143 REMOVAL ......................................................... 143 INSPECTION AFTER REMOVAL ..................... 143 INSTALLATION ................................................. 144 FUEL INJECTOR AND FUEL TUBE ...................... 145 Removal and Installation ...................................... 145 REMOVAL ......................................................... 145 INSTALLATION ................................................. 148 INSPECTION AFTER INSTALLATION .............. 150 ROCKER COVER ................................................... 151 Removal and Installation ...................................... 151 REMOVAL (LEFT BANK) .................................. 151 INSTALLATION (LEFT BANK) .......................... 152 REMOVAL (RIGHT BANK) ................................ 153 INSTALLATION (RIGHT BANK) ........................ 154 FRONT TIMING CHAIN CASE ............................... 156 Removal and Installation ...................................... 156 REMOVAL ......................................................... 156 INSTALLATION ................................................. 160 INSPECTION AFTER INSTALLATION .............. 163 TIMING CHAIN ........................................................ 165 Removal and Installation ...................................... 165 REMOVAL ......................................................... 166 INSPECTION AFTER REMOVAL ..................... 173 INSTALLATION ................................................. 174 INSPECTION AFTER INSTALLATION .............. 184 CAMSHAFT ............................................................ 185 Removal and Installation ...................................... 185 REMOVAL ......................................................... 186 INSPECTION AFTER REMOVAL ..................... 187 INSTALLATION ................................................. 190 INSPECTION AFTER INSTALLATION .............. 193 Valve Clearance ................................................... 194 INSPECTION .................................................... 194 ADJUSTMENT .................................................. 197 OIL SEAL ................................................................ 199 Removal and Installation of Valve Oil Seal ........... 199 REMOVAL ......................................................... 199 INSTALLATION ................................................. 199 Removal and Installation of Front Oil Seal ........... 200 REMOVAL ......................................................... 200

EM-3

2006 Frontier

INSTALLATION .................................................. 200 Removal and Installation of Rear Oil Seal ............ 200 REMOVAL ......................................................... 200 INSTALLATION .................................................. 201 CYLINDER HEAD ................................................... 202 On-Vehicle Service ............................................... 202 CHECKING COMPRESSION PRESSURE ....... 202 Removal and Installation ...................................... 203 REMOVAL ......................................................... 203 INSPECTION AFTER REMOVAL ...................... 204 INSTALLATION .................................................. 205 INSPECTION AFTER INSTALLATION .............. 206 Disassembly and Assembly .................................. 207 DISASSEMBLY ................................................. 207 ASSEMBLY ....................................................... 208 Inspection After Disassembly ............................... 209 VALVE DIMENSIONS ........................................ 209 VALVE GUIDE CLEARANCE ............................ 209 VALVE GUIDE REPLACEMENT ....................... 210 VALVE SEAT CONTACT ................................... 211 VALVE SEAT REPLACEMENT ......................... 211 VALVE SPRING SQUARENESS ....................... 212 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ............................. 213 ENGINE ASSEMBLY .............................................. 214 Removal and Installation ...................................... 214 REMOVAL ......................................................... 215 INSTALLATION .................................................. 216 INSPECTION AFTER INSTALLATION .............. 216 CYLINDER BLOCK ................................................. 217 Disassembly and Assembly .................................. 217 DISASSEMBLY ................................................. 218 ASSEMBLY ....................................................... 222 How to Select Piston and Bearing ........................ 228 DESCRIPTION .................................................. 228 HOW TO SELECT PISTON ............................... 228 HOW TO SELECT CONNECTING ROD BEARING .................................................................... 229 HOW TO SELECT MAIN BEARING .................. 230 Inspection After Disassembly ............................... 233 CRANKSHAFT END PLAY ................................ 233 CONNECTING ROD SIDE CLEARANCE ......... 233 PISTON TO PISTON PIN OIL CLEARANCE .... 233 PISTON RING SIDE CLEARANCE ................... 234 PISTON RING END GAP .................................. 234 CONNECTING ROD BEND AND TORSION ..... 235 CONNECTING ROD BIG END DIAMETER ...... 235 CONNECTING ROD BUSHING OIL CLEAR-

Revision: September 2005

ANCE ................................................................. 235 CYLINDER BLOCK DISTORTION .................... 236 MAIN BEARING HOUSING INNER DIAMETER.237 PISTON TO CYLINDER BORE CLEARANCE . 237 CRANKSHAFT MAIN JOURNAL DIAMETER ... 238 CRANKSHAFT PIN JOURNAL DIAMETER ...... 239 CRANKSHAFT OUT-OF-ROUND AND TAPER.239 CRANKSHAFT RUNOUT .................................. 239 CONNECTING ROD BEARING OIL CLEARANCE ................................................................. 239 MAIN BEARING OIL CLEARANCE ................... 240 CRUSH HEIGHT OF MAIN BEARING .............. 241 CRUSH HEIGHT OF CONNECTING ROD BEARING ........................................................... 241 LOWER CYLINDER BLOCK BOLT OUTER DIAMETER ........................................................ 241 CONNECTING ROD BOLT OUTER DIAMETER.242 FLYWHEEL DEFLECTION (M/T MODELS) ...... 242 MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS) ........................................................... 242 DRIVE PLATE .................................................... 243 OIL JET .............................................................. 243 OIL JET RELIEF VALVE .................................... 243 SERVICE DATA AND SPECIFICATIONS (SDS) .... 244 Standard and Limit ................................................ 244 GENERAL SPECIFICATIONS ........................... 244 DRIVE BELT ...................................................... 245 INTAKE MANIFOLD COLLECTOR, INTAKE MANIFOLD AND EXHAUST MANIFOLD .......... 245 SPARK PLUG .................................................... 245 CAMSHAFT AND CAMSHAFT BEARING ......... 246 CYLINDER HEAD .............................................. 248 CYLINDER BLOCK ............................................ 251 PISTON, PISTON RING AND PISTON PIN ...... 252 CONNECTING ROD .......................................... 253 CRANKSHAFT ................................................... 254 MAIN BEARING ................................................. 255 CONNECTING ROD BEARING ......................... 256

EM-4

2006 Frontier

PRECAUTIONS [QR]

PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

EBS00T36

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along EM with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. C WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be perD formed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air E Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. F

Precautions for Drain Engine Coolant and Engine Oil

EBS00NGC

Drain engine coolant and engine oil when the engine is cooled.

Precautions for Disconnecting Fuel Piping ● ● ●

● ● ● ●

EBS00NGD

Before starting work, make sure no fire or spark producing items are in the work area. Release fuel pressure before disassembly. After disconnecting pipes, plug openings to stop fuel leakage.

Precautions for Removal and Disassembly ●

EBS00NGE

When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. Exercise maximum care to avoid damage to mating or sliding surfaces. Cover openings of engine system with a tape or the equivalent, if necessary, to seal out foreign materials. Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used where noted in the step.

Precautions for Inspection, Repair and Replacement

● ●

●

EBS00NGG

Use torque wrench to tighten bolts or nuts to specification. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified. Replace with new gasket, packing, oil seal or O-ring. Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins, make sure that dowel pins are installed in the original position. Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well. Release air within route when refilling after draining engine coolant.

Revision: September 2005

EM-5

EBS00NGF

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.

Precautions for Assembly and Installation

2006 Frontier

PRECAUTIONS [QR] ●

●

Before starting the engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with the engine stopped). Then make sure there are no leaks at fuel line connections. After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

Parts Requiring Angle Tightening ●

For the final tightening of the following engine parts use Tool: Tool number

– – – –

● ● ●

EBS00NGH

: KV10112100 (BT-8653-A)

Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts Crankshaft pulley bolt (No angle wrench is required as bolt flange is provided with notches for angle tightening) Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.

Precautions for Liquid Gasket

EBS00NGI

REMOVAL OF LIQUID GASKET SEALING ●

After removing nuts and bolts, separate the mating surface and remove old liquid gasket sealing using Tool. Tool number

●

: KV10111100 (J-37228)

CAUTION: Be careful not to damage the mating surfaces. Tap seal cutter to insert it, and then slide it by tapping on the side as shown. In areas where Tool is difficult to use, use plastic hammer to lightly tap the parts, to remove it. CAUTION: If for some unavoidable reason tool such as screwdriver is used, be careful not to damage the mating surfaces.

WBIA0566E

LIQUID GASKET APPLICATION PROCEDURE 1.

Using scraper, remove old liquid gasket adhering to the gasket application surface and the mating surface. ● Remove liquid gasket completely from the groove of the gasket application surface, bolts, and bolt holes. Thoroughly clean the mating surfaces and remove adhering moisture, grease and foreign materials.

PBIC0003E

Attach liquid gasket tube to Tool. Tool number

: WS39930000 (

—

)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" . Apply liquid gasket without breaks to the specified location with the specified dimensions. ● If there is a groove for liquid gasket application, apply liquid gasket to the groove. WBIA0567E

Revision: September 2005

EM-6

2006 Frontier

PRECAUTIONS [QR] As for bolt holes, normally apply liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of this manual. ● Within five minutes of liquid gasket application, install the mating component. ● If liquid gasket protrudes, wipe it off immediately. ● Do not retighten nuts or bolts after the installation. ● After 30 minutes or more have passed from the installation, fill engine oil and engine coolant. CAUTION: If there are specific instructions in this manual, observe them. ●

SEM159F

Revision: September 2005

EM-7

2006 Frontier

PREPARATION [QR]

PREPARATION Special Service Tools

PFP:00002 EBS00NGJ

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. Tool number Description (Kent-Moore No.) Tool name KV10111100 (J-37228) Seal cutter

Removing oil pan and front cover, etc.

S-NT046

KV10116200 (J-26336-A) Valve spring compressor 1. KV10115900 (J-26336-20) Attachment 2. KV10109220 ( â&#x20AC;&#x201D; ) Adapter

Disassembling valve mechanism Part (1) is a component of KV10116200 (J26336-A), but Part (2) is not so.

PBIC1650E

KV10112100 (BT-8653-A) Angle wrench

Tightening bolts for connecting rod bearing cap, cylinder head, etc. in angle

NT014

KV10117100 (J-36471-A) Heated oxygen sensor wrench

Loosening or tightening air fuel ratio sensor 1 For 22 mm (0.87 in) width hexagon nut

NT379

KV10107902 (J-38959) Valve oil seal puller

Replacing valve oil seal

NT011

KV10115600 (J-38958) Valve oil seal drift

Installing valve oil seal

NT024

Revision: September 2005

EM-8

2006 Frontier

PREPARATION [QR] Tool number (Kent-Moore No.) Tool name

Description

EM03470000 (J-8037) Piston ring compressor

Installing piston assembly into cylinder bore

C NT044

ST16610001 (J-23907) Pilot bushing puller

Removing pilot bushing (M/T models) or pilot converter (A/T models)

E NT045

WS39930000 ( — ) Tube presser

Pressing the tube of liquid gasket

NT052

— (J-45488) Quick connector release

Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210)

J PBIC0198E

— (J-46535) Drive belt tension releaser

Releasing drive belt tension

L WBIA0536E

— (J-44626) Air fuel sensor Socket

Loosening or tightening air fuel ratio A/F sensor a: 22 mm (0.87 in)

LBIA0444E

KV10114400 (J-38365) Heated oxygen sensor wrench

Loosening or tightening heated oxygen sensor 1 a: 22 mm (0.87 in)

NT636

Revision: September 2005

EM-9

2006 Frontier

PREPARATION [QR]

Commercial Service Tools

EBS00NGK

(Kent-Moore No.) Tool name

Description

Power tool

Loosening nuts and bolts

PBIC0190E

( — ) Spark plug wrench

Removing and installing spark plug

PBIC2982E

( — ) Pulley holder

Removing and installing crankshaft pulley

ZZA1010D

( — ) Pulley puller

Removing crankshaft pulley

NT676

( — ) 1. Compression tester 2. Adapter

Checking compression pressure

ZZA0008D

(J-24239-01) Cylinder head bolt wrench

Loosening and tightening cylinder head bolt, and used with the angle wrench [SST: KV10112100 (BT8653-A)] a: 13 (0.51) dia. b: 12 (0.47) c: 10 (0.39) Unit: mm (in) NT583

( — ) Valve seat cutter set

Finishing valve seat dimensions

S-NT048

Revision: September 2005

EM-10

2006 Frontier

PREPARATION [QR] (Kent-Moore No.) Tool name

Description

TORX socket

Removing and installing flywheel Size: T55

C PBIC1113E

Deep socket

Removing and installing oil pressure switch a: 27 mm (1.06 in)

E PBIC2072E

( — ) Piston ring expander

Removing and installing piston ring

G S-NT030

( — ) Valve guide drift

Removing and installing valve guide Intake and Exhaust: a: 9.5 mm (0.374 in) dia. b: 5.5 mm (0.217 in) dia.

S-NT015

( — ) Valve guide reamer

1: Reaming valve guide inner hole 2: Reaming hole for oversize valve guide Intake and Exhaust: d1 : 6.0 mm (0.236 in) dia. d2 : 10.2 mm (0.402 in) dia.

L S-NT016

a: (J-43897-18) b: (J-43897-12) Oxygen sensor thread cleaner

Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) a = 18 mm (0.71 in) dia. for zirconia heated oxygen sensor b = 12 mm (0.47 in) dia. for titania heated oxygen sensor AEM488

Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads

( — ) Anti-seize lubricant i.e.: (PermatexTM 133AR or equivalent meeting MIL specification MIL-A-907)

AEM489

Revision: September 2005

EM-11

2006 Frontier

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [QR]

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting â&#x20AC;&#x201D; Engine Noise

PFP:00003 EBS00NHK

PBIC2983E

Revision: September 2005

EM-12

2006 Frontier

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [QR]

Use the Chart Below to Help You Find the Cause of the Symptom.

EBS00NHL

1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts.

Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head

Type of noise

Front of engine

When starting

When idling

When racing

—

Rattle

—

Slap or rap

Knock

Front of engine Front cover

After warmup

Ticking or clicking

Slap or knock

Crankshaft pulley Cylinder block (Side of engine) Oil pan

Before warmup

Tapping or ticking

—

While driving

Source of noise

Reference page

Check item

—

Tappet noise

Valve clearance

EM-103

Camshaft bearing noise

Camshaft journal oil clearance Camshaft runout

EM-39 EM-38

—

Piston pin noise

Piston to piston pin oil clearance Connecting rod bushing oil clearance

EM-92 EM-94

Piston slap noise

Piston to cylinder bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion

EM-96 EM-93 EM-93 EM-94

Connecting rod bearing noise

Connecting rod bushing oil clearance Connecting rod bearing oil clearance

EM-94 EM-98

Main bearing noise

Main bearing oil clearance Crankshaft runout

EM-99 EM-98

Timing chain and chain tensioner noise

Timing chain cracks and wear Timing chain tensioner operation

EM-52 EM-48

Drive belt (Sticking or slipping)

Drive belt deflection

Squeaking or fizzing

Creaking

Drive belt (Slipping)

Idler pulley bearing operation

Squall Creak

—

Water pump noise

Water pump operation

A: Closely related

B: Related

Revision: September 2005

—

C: Sometimes related

—

M EM-14

CO-19, "WATER PUMP"

—: Not related

EM-13

2006 Frontier

DRIVE BELTS [QR]

DRIVE BELTS Checking Drive Belt

PFP:02117 EBS00NHM

LBIA0438E

Drive belt

Power steering oil pump pulley

Generator pulley

Crankshaft pulley

A/C compressor (if equipped) or idler pulley

Idler pulley

Water pump

Idler pulley

Drive belt auto- tensioner

WARNING: ● Be sure to perform this step when the engine is stopped. ● Make sure that the indicator (fixed side) of the drive belt auto-tensioner is within the possible use range (moving side) as shown. NOTE: ● On vehicles not equipped with A/C, there is an idler pulley in the A/C compressor position for the drive belt routing. ● Check the drive belt auto-tensioner indication when the engine is cold. ● Visually check entire drive belt for wear, damage or cracks. ● When new drive belt is installed, the indicator (fixed side) should be within the range "A". If the indicator (fixed side) is out of the possible use range or drive belt is damaged, replace drive belt.

Tension Adjustment

EBS00NHN

Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Removal and Installation

EBS00NIG

REMOVAL 1.

Install Tool on auto tensioner pulley bolt, move in the direction of arrow (loosening direction of tensioner) using Tool. Tool number

—

(J-46535)

CAUTION: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. ● Do not loosen the auto-tensioner pulley bolt. (Do not turn it counterclockwise.) If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including pulley. Remove drive belt. ●

Revision: September 2005

EM-14

LBIA0439E

2006 Frontier

DRIVE BELTS [QR] INSTALLATION A Installation is in the reverse order of removal. CAUTION: ● Do not loosen the auto-tensioner pulley bolt. (Do not turn it counterclockwise.) If turned counterEM clockwise, the complete auto-tensioner must be replaced as a unit, including pulley. ● Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. C ● Confirm belts are completely set on the pulleys. ● Check that there are no engine working fluids on the drive belt or pulley grooves. NOTE: D ● Turn crankshaft pulley clockwise several times to equalize tension between each pulley. ● Confirm tension of drive belt indicator (fixed side) is within the possible use range.

Removal and Installation of Drive Belt Auto-Tensioner

E EBS00NHP

K LBIA0440E

REMOVAL 1. 2. 3. 4. 5.

Remove air cleaner and air duct EM-16, "REMOVAL" . Remove drive belt. Refer to EM-14, "REMOVAL" . Remove the power steering oil pump and position aside. Refer to PS-22, "REMOVAL" . Remove generator. Refer to SC-37, "REMOVAL" . Remove drive belt auto-tensioner.

INSTALLATION Installation is in the reverse order of removal. CAUTION: If there is damage greater than peeled paint, replace drive belt auto-tensioner.

Revision: September 2005

EM-15

2006 Frontier

AIR CLEANER AND AIR DUCT [QR]

AIR CLEANER AND AIR DUCT Removal and Installation

PFP:16500 EBS00NHR

LBIA0441E

Air cleaner case

Air duct and resonator assembly

Intake manifold

Air cleaner filter

Air duct

REMOVAL 1. 2.

Remove two bolts and remove air duct. ● Add mating marks as necessary for easier installation. Remove resonator in fender lifting left fender protector, as necessary.

INSPECTION AFTER REMOVAL Inspect air duct assembly for cracks or tear. ● Replace air duct assembly, if necessary.

INSTALLATION Installation is in the reverse order of removal. ● Align marks. Attach each joint. Screw clamps firmly. ● Install duct to intake manifold by aligning "LOCK-UNLOCK" upward.

Revision: September 2005

EM-16

2006 Frontier

AIR CLEANER AND AIR DUCT [QR]

Changing Air Cleaner Filter

EBS00NHS

REMOVAL 1. 2.

Unfasten clips and lift up air cleaner case upper. Remove air cleaner filter. EM

D LBIA0442E

INSTALLATION

Installation is in the reverse order of removal.

Revision: September 2005

EM-17

2006 Frontier

INTAKE MANIFOLD [QR]

INTAKE MANIFOLD Removal and Installation

PFP:14003 EBS00NHT

WBIA0733E

Vacuum hose

Vacuum hose adapter

O–ring

Vacuum hose

EVAP canister purge volume control solenoid valve

Vacuum hose

Service port

Collar

Grommet

10. Intake manifold support

11. Vacuum hose

13. Intake manifold

14. Fuel tube protector

12. Gasket 15. Air cleaner

16. Air cleaner case

17. PCV hose

18. Gasket

19. PCV hose

20. Water hose

21. Water hose

22. Air duct

23. Electric throttle control actuator

24. Mass air flow sensor

To vacuum pipe (EVAP canister)

To brake booster

To PCV valve

To heater outlet

To heater pipe

To rocker cover

→

Engine front

CAUTION: Do not remove or disassemble parts unless instructed as shown in the figure.

REMOVAL 1. 2. 3.

Release fuel pressure. Refer to EC-86, "FUEL PRESSURE RELEASE" . Remove air cleaner case, air cleaner and air duct. Disconnect water hoses from electric throttle control actuator, and pinch water hoses near electric throttle control actuator to prevent engine coolant spilling. CAUTION: ● Perform this step when engine is cold.

Revision: September 2005

EM-18

2006 Frontier

INTAKE MANIFOLD [QR] ●

Do not spill engine coolant on drive belt. A

Remove mass air flow sensor from intake manifold. CAUTION: Handle the mass air flow sensor with care: ● Do not shock it. ● Do not disassemble it. ● Do not touch the internal sensor. Remove quick connector cap, and disconnect quick connector at the engine side. Refer to EM-29, "FUEL INJECTOR AND FUEL TUBE" .

F LBIA0450E

6. a. b.

Remove electric throttle control actuator with the following procedure: Disconnect harness connector. Loosen bolts in reverse order as shown, and remove electric throttle control actuator and gasket. CAUTION: ● Handle carefully to avoid any shock to electric throttle control actuator. ● Do not disassemble.

PBIC2987E

7. 8. 9.

Disconnect harness, vacuum hoses and PCV hoses from intake manifold, and move them aside. Remove intake manifold support. Loosen nuts and bolts in reverse order as shown, and remove intake manifold, fuel tube protector and gasket. CAUTION: ● Cover engine openings to avoid entry of foreign materials. ● Do not disassemble intake manifold. NOTE: Disregard No. 6 when loosening.

PBIC2988E

10. Remove EVAP canister purge volume control solenoid valve and vacuum hose adapter from intake manifold, if necessary. 11. Disconnect sub-harness from fuel injector. Refer to EM-29, "FUEL INJECTOR AND FUEL TUBE" . 12. Remove fuel tube and fuel injector assembly from intake manifold. Refer to EM-29, "FUEL INJECTOR AND FUEL TUBE" .

INSTALLATION Installation in the reverse order of removal. Revision: September 2005

EM-19

2006 Frontier

INTAKE MANIFOLD [QR] Intake Manifold and Fuel Tube Protector ●

If stud bolts were removed, install them and tighten to the specified torque below. Intake manifold bolts

●

: 9.4 N·m (0.96 kg-m, 83in-lb)

Tighten in numerical order as shown. NOTE: No. 6 means double tightening of bolt No. 1. Refer to the following for locating bolts and nuts. M8 x 38 mm (1.50 in) (Color green) : No. 1, 6 M8 x 35 mm (1.38 in) : No. 2, 3 Nut : No. 4, 5 PBIC2988E

Electric Throttle Control Actuator ●

●

Tighten bolts equally and diagonally in several steps and in numerical order as shown. Perform the “Throttle Valve Closed Position Learning” when harness connector of electric throttle control actuator is disconnected. Refer to EC-84, "Throttle Valve Closed Position Learning" . Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when electric throttle control actuator is replaced. Refer to EC-84, "Idle Air Volume Learning" . PBIC2987E

INSPECTION AFTER INSTALLATION Make sure there are no fuel leaks at connections with the following procedure: 1. Apply fuel pressure to fuel lines with turning ignition switch “ON” (with the engine stopped). Then make sure there are no fuel leaks at connections. NOTE: Use mirrors for checking on invisible points. 2. Start the engine. With engine speed increased, make sure again there are no fuel leaks at connections. CAUTION: Do not touch the engine immediately after stopped as the engine becomes extremely hot.

Revision: September 2005

EM-20

2006 Frontier

EXHAUST MANIFOLD AND THREE WAY CATALYST [QR]

EXHAUST MANIFOLD AND THREE WAY CATALYST Removal and Installation

PFP:14004

A EBS00NHU

I WBIA0647E

Air fuel ratio sensor 1

Exhaust manifold and three way catalyst assembly 3.

Bracket

Exhaust manifold cover

Gasket

REMOVAL 1. 2.

Release fuel pressure. Refer to EC-689, "FUEL PRESSURE RELEASE" . Remove quick connector cap, and disconnect quick connector at the engine side. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .

LBIA0450E

3. 4. 5.

Remove air duct, PCV hose (between air duct and rocker cover) and electric throttle control actuator. Refer to EM-18, "INTAKE MANIFOLD" . Disconnect harness connector of air fuel ratio sensor 1, and harness from bracket and middle clamp. Remove air fuel ratio sensor 1 using Tool. Tool number

—

(J-44626)

CAUTION: ● Be careful not to damage air fuel ratio sensor 1. ● Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new one. Revision: September 2005

EM-21

2006 Frontier

EXHAUST MANIFOLD AND THREE WAY CATALYST [QR] 6. 7. 8. 9.

Remove exhaust front tube. Refer to EX-6, "REMOVAL" . Remove exhaust manifold cover. Remove bracket between exhaust manifold–three way catalyst assembly and transmission assembly. Loosen nuts in reverse order as shown to remove exhaust manifold and three way catalyst assembly.

PBIC2990E

10. Remove gasket. CAUTION: Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL Surface Distortion ●

Using a straightedge and a feeler gauge, check the surface distortion of exhaust manifold and three way catalyst assembly mating surface. Limit

●

: 0.3 mm (0.012 in)

If it exceeds the limit, replace exhaust manifold and three way catalyst assembly.

PBIC2991E

INSTALLATION installation is in the reverse order of removal.

Exhaust Manifold 1.

If stud bolts were removed, install them and tighten to the specified torque below. Exhaust manifold stud bolt

2. 3.

: 14.7 N·m (1.5 kg-m, 11 ft-lb)

Tighten nuts in numerical order as shown. Tighten nuts in numerical order as shown again.

PBIC2990E

Air Fuel Ratio Sensor 1 CAUTION: ● Before installing new air fuel ratio sensor 1, clean exhaust system threads using a heated oxygen sensor thread cleaner (commercial service tool: J-43897-18 or J-43897-12) and apply anti-seize lubricant (commercial service tool). ● Do not over torque air fuel ratio sensor 1. Doing so may cause damage to air fuel ratio sensor 1, resulting in the “MIL” coming on. Revision: September 2005

EM-22

2006 Frontier

OIL PAN [QR]

OIL PAN Removal and Installation

PFP:11110

A EBS00NHV

G PBIC2992E

Oil pan

Drain plug washer

A/T fluid cooler tube bracket (A/T models)

Drain plug

REMOVAL WARNING: To avoid the danger of being scalded, do not drain the engine oil when the engine is hot. 1. Remove engine undercover. 2. Drain engine oil. Refer to MA-26, "Changing Engine Oil" . CAUTION: â&#x2014;? Perform this step when the engine is cold. â&#x2014;? Do not spill engine oil on drive belt. 3. Remove oil pan with the following procedure: a. Remove A/T fluid cooler tube (A/T models). Refer to AT-247, "TRANSMISSION ASSEMBLY" . b. Loosen bolts in reverse order as shown with power tool. Remove A/T fluid cooler tube bracket (A/T models).

PBIC2993E

Insert the seal cutter [SST] between oil pan and cylinder block, and slide it by tapping on the side of the tool with a hammer. Remove oil pan.

Revision: September 2005

EM-23

2006 Frontier

OIL PAN [QR] Tool number

: KV10111100 (J-37228)

CAUTION: ● Be careful not to damage the mating surfaces. ● Do not insert a screwdriver, this will damage the mating surfaces.

WBIA0566E

INSTALLATION 1. a.

Install oil pan with the following procedure: Use a scraper to remove old liquid gasket from mating surfaces. ● Also remove the old liquid gasket from mating surface of cylinder block. ● Remove old liquid gasket from the bolt holes and threads. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.

PBIC2994E

Apply a continuous bead of liquid gasket using Tool as shown. Tool number

: WS39930000 (

—

)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" . CAUTION: Attaching should be done within 5 minutes after coating.

PBIC2984E

Tighten bolts in numerical order as shown. ● Install A/T fluid cooler tube bracket with bolts No.1 and 9 as shown (A/T models).

PBIC2993E

2. 3.

Install oil pan drain plug. Refer to MA-26, "Changing Engine Oil" . Install in the reverse order of removal after this step. NOTE: Pour engine oil at least 30 minutes after oil pan is installed.

INSPECTION AFTER INSTALLATION 1.

Check the engine oil level, and adjust the level. Refer to LU-6, "ENGINE OIL LEVEL" .

Revision: September 2005

EM-24

2006 Frontier

OIL PAN [QR] 2. 3. 4.

Start the engine, and make sure there is no leaks of engine oil. Stop the engine and wait for 10 minutes. Check the engine oil level again. Refer to LU-6, "ENGINE OIL LEVEL" .

Revision: September 2005

EM-25

2006 Frontier

IGNITION COIL [QR]

IGNITION COIL Removal and Installation

PFP:22448 EBS00NHW

WBIA0648E

Ignition coil

Spark plug

Rocker cover

REMOVAL 1. 2. 3.

Remove intake manifold (except for ignition coil No.1). Refer to EM-18, "INTAKE MANIFOLD" . Disconnect harness connector from ignition coil. Remove ignition coil. CAUTION: Do not drop or shock it.

INSTALLATION Installation is in the reverse order of removal.

Revision: September 2005

EM-26

2006 Frontier

SPARK PLUG (PLATINUM-TIPPED TYPE) [QR]

SPARK PLUG (PLATINUM-TIPPED TYPE) Changing Spark Plugs (Platinum - Tipped Type)

PFP:22401

A EBS00T2Y

G PBIC2995E

Ignition coil

Spark plug

Rocker cover

REMOVAL

1. 2. 3.

Remove the intake manifold (except for spark plug No.1). Refer to EM-18, "INTAKE MANIFOLD" . Remove the ignition coil. Refer to EM-26, "IGNITION COIL" . Remove the spark plug using a suitable tool.

L PBIC2996E

INSPECTION AFTER REMOVAL ●

Do not use a wire brush to clean the spark plug.

SMA773C

●

If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure Cleaning time

Revision: September 2005

: Less than 588 kPa (5.9 bar, 6 kg/cm2 , 85 psi) : Less than 20 seconds

EM-27

2006 Frontier

SPARK PLUG (PLATINUM-TIPPED TYPE) [QR] ●

Checking and adjusting plug gap is not required between change intervals.

SMA806CA

CAUTION: Do not drop or shock the spark plug.

INSTALLATION Installation is in the reverse order of removal. ● Use the standard type spark plug for normal driving conditions. ● The hot type spark plug is suitable (when fouling occurs with the standard type spark plug) under conditions such as: – frequent engine starts – low ambient temperatures ● The cold type spark plug is suitable (when engine spark knock occurs with the standard type spark plug) under conditions such as: – extended highway driving – frequent high engine revolution Spark Plug Types Make

NGK

Standard type

PLKAR6A-11

Hot type

PLKAR5A-11

Cold type

PLKAR7A-11

Gap (nominal)

1.1 mm (0.043 in)

CAUTION: Do not drop or shock the spark plug.

Revision: September 2005

EM-28

2006 Frontier

FUEL INJECTOR AND FUEL TUBE [QR]

FUEL INJECTOR AND FUEL TUBE Removal and Installation

PFP:16600

A EBS00NHY

G WBIA0649E

Fuel feed hose

Quick connector cap (engine side)

Sub-harness

Fuel tube

O-ring (black)

Clip

Fuel injector

O-ring (green)

CAUTION: Do not remove or disassemble parts unless instructed as shown.

REMOVAL WARNING: ● Put a “CAUTION: INFLAMMABLE” sign in the workshop. ● Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. ● Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area. 1. Release fuel pressure. Refer to EC-689, "FUEL PRESSURE RELEASE" .

LBIA0450E

Remove quick connector cap (engine side).

KBIA0701E

Revision: September 2005

EM-29

2006 Frontier

FUEL INJECTOR AND FUEL TUBE [QR] 3. 4.

With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube. Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position. Tool number

—

(J-45488)

CAUTION: Disconnect quick connector by using tool, not by picking out retainer tabs. CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. Draw and pull out quick connector straight from fuel tube. CAUTION: ● Pull quick connector holding “A” position in the figure. ● Do not pull with lateral force applied. O-ring inside quick KBIA0702E connector may be damaged. ● Prepare container and cloth beforehand as fuel will leak out. ● Avoid fire and sparks. ● Keep parts away from heat source. Especially, be careful when welding is performed around them. ● Do not expose parts to battery electrolyte or other acids. ● Do not bend or twist connection between quick connector and fuel feed hose during installation/removal. ● To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.

PBIC2205E

6. 7. 8. 9.

Remove intake manifold. Refer to EM-18, "REMOVAL" . Disconnect sub-harness for fuel injector. Loosen bolts in reverse order as shown. Remove fuel tube and fuel injector assembly. CAUTION: ● When removing, be careful to avoid any interference with fuel injector. ● Use a shop cloth to absorb any fuel leaks from fuel tube.

PBIC2998E

Revision: September 2005

EM-30

2006 Frontier

FUEL INJECTOR AND FUEL TUBE [QR] 10. Remove fuel injector from fuel tube with the following procedure: a. Open and remove clip. b. Remove fuel injector from fuel tube by pulling straight. CAUTION: ● Be careful with remaining fuel that may go out from fuel tube. ● Be careful not to damage fuel injector nozzle during removal. ● Do not bump or drop fuel injector. ● Do not disassemble fuel injector.

G PBIC2999E

INSTALLATION 1.

Note the following, and install O-rings to fuel injector. CAUTION: ● Upper and lower O-rings are different. Be careful not to confuse them. Fuel tube side Nozzle side ● ● ● ● ●

: Black : Green

Handle O-ring with bare hands. Do not wear gloves. Lubricate O-ring with new engine oil. Do not clean O-ring with solvent. Make sure that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube.

Revision: September 2005

EM-31

2006 Frontier

FUEL INJECTOR AND FUEL TUBE [QR] Insert O-ring straight into fuel tube. Do not decenter or twist it. Insert clip into clip attachment groove on fuel injector. CAUTION: ● Do not reuse clip. Replace it with a new one. ● Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube with clip attached. ● Insert it while matching it to the axial center. ● Insert fuel injector so that protrusion of fuel tube matches cutout of clip. ● Make sure that fuel tube flange is securely fixed in flange fixing groove on clip. Make sure that installation is complete by checking that fuel injector does not rotate or come off. ●

PBIC3000E

a. b.

Install fuel tube and fuel injector assembly with the following procedure: CAUTION: When installing, be careful to avoid any interference with fuel injector. Insert the tip of each fuel injector into intake manifold. Tighten bolts evenly in two steps in numerical order as shown. Fuel tube bolts 1st step 2nd step

: 12.8 N·m (1.3 kg-m, 9 ft-lb) : 28.0 N·m (2.9 kg-m, 21 ft-lb)

PBIC2998E

6. 7. 8. a. b.

Connect sub-harness for fuel injector. Install intake manifold. Refer to EM-19, "INSTALLATION" . Note the following, and connect quick connector at the engine side to install fuel feed hose. Check the connection for foreign material and damage. Align center to insert quick connector straightly into fuel tube. NOTE: The figure shows the engine side as an example. ● Insert quick connector to fuel tube until the top spool on fuel tube is inserted completely and the second level spool is positioned slightly below quick connector bottom end. CAUTION: ● Hold “A” position in the figure when inserting fuel tube into quick connector. ● Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. ● Insert until you hear a “click” sound and actually feel the engagement.

Revision: September 2005

EM-32

KBIA0272E

2006 Frontier

FUEL INJECTOR AND FUEL TUBE [QR] To avoid misidentification of engagement with a similar sound, be sure to perform the next step. A c. Before clamping fuel feed hose with hose clamps, pull quick connector hard by hand holding “A” position. Make sure it is completely engaged (connected) so that it does not come out from fuel feed tube. d. Install quick connector cap to quick connector connection. EM (engine side) ● Install so that the arrow mark on the side faces up. C CAUTION: ● Make sure that quick connector and fuel tube are securely fit into quick connector cap installation groove. ● If quick connector cap cannot be installed smoothly, D quick connector may have not been installed correctly. Check the connection again. 9. Install fuel feed hose to hose clamp. E PBIC2348E 10. Installation is in the reverse order of removal after this step. ●

INSPECTION AFTER INSTALLATION Check on Fuel Leaks 1.

Apply fuel pressure to fuel lines with turning ignition switch “ON” (with the engine stopped). Then make sure there are no fuel leaks at connections. NOTE: Use mirrors for checking on invisible points. Start the engine. With engine speed increased, make sure again there are no fuel leaks at connections. CAUTION: Do not touch the engine immediately after stopped as the engine becomes extremely hot.

Revision: September 2005

EM-33

2006 Frontier

ROCKER COVER [QR]

ROCKER COVER Removal and Installation

PFP:13264 EBS00NHZ

WBIA0650E

PCV hose

PCV valve

O-ring

Oil filler cap

Rocker cover

Rocker cover gasket

PCV hose

REMOVAL 1. 2. 3. 4. 5. 6.

Remove intake manifold. Refer to EM-18, "INTAKE MANIFOLD" . Disconnect PCV hose from rocker cover. Remove ignition coil. Refer to EM-26, "IGNITION COIL" . Remove PCV valve and O-ring from rocker cover, if necessary. Remove oil filler cap from rocker cover, if necessary. Loosen bolts in reverse order shown.

PBIC3003E

7. 8.

Remove rocker cover gasket from rocker cover. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1). CAUTION: Do not scratch or damage the mating surface when cleaning off old liquid gasket.

Revision: September 2005

EM-34

2006 Frontier

ROCKER COVER [QR] INSTALLATION 1. a. b.

Apply liquid gasket to the position shown with the following procedure: Refer to figure “a” to apply liquid gasket to joint part of camshaft bracket (No. 1) and cylinder head. Refer to figure “b” to apply liquid gasket in 90° to figure “a”. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" .

G PBIC2635E

2. 3. 4.

Install new rocker cover gasket to rocker cover. Install rocker cover. ● Check if rocker cover gasket is not dropped from the installation groove of rocker cover. Tighten bolts in two steps separately in numerical order as shown.

Rocker cover bolts 1st step : 2.0 N·m (0.2 kg-m, 18 in-lb) 2nd step : 8.3 N·m (0.85 kg-m, 73 in-lb) 5.

Installation of the remaining components is in the reverse order of removal.

Revision: September 2005

EM-35

2006 Frontier

CAMSHAFT [QR]

CAMSHAFT Removal and Installation

PFP:13001 EBS00NI0

WBIA0651E

Camshaft bracket (No. 2 to 5)

Seal washer

Camshaft bracket (No. 1)

Front cover

Chain guide

Chain tensioner

Spring

Chain tensioner plunger

O-ring

12.

Intake valve timing control solenoid valve

10. Oil ring

11. O-ring

13. Intake valve timing control cover

14. Camshaft sprocket (INT)

15. Camshaft sprocket (EXH)

16. O-ring

17. Valve lifter

18. Camshaft (INT)

19. Camshaft (EXH)

20. O-ring

21. Camshaft position sensor (PHASE)

NOTE: This section describes removal/installation procedure of camshaft without removing front cover. If front cover is removed or installed, refer to EM-48, "TIMING CHAIN" .

REMOVAL 1. 2. 3. 4. 5.

Remove the rocker cover. Refer to EM-34, "REMOVAL" . Remove the drive belt. Refer to EM-14, "REMOVAL" . Disconnect and remove the camshaft position sensor (PHASE). Disconnect the IVT control solenoid electrical connector. Disconnect the ground electrical connections from the front cover.

Revision: September 2005

EM-36

2006 Frontier

CAMSHAFT [QR] 6. 7.

Remove IVT control cover bolts in the order as shown. Remove the IVT control cover by cutting the sealant using Tool. Tool number

: KV10111100 (J-37228) EM

C KBIA0085E

8. 9.

Set the No.1 cylinder at TDC on its compression stroke with the following procedure: Rotate crankshaft pulley clockwise, and align mating marks for TDC with timing indicator on front cover, as shown.

G KBIA0190E

10. At the same time, make sure that the mating marks on camshaft sprockets are lined up with the yellow links in the timing chain, as shown. â&#x2014;? If not, rotate crankshaft pulley one more turn to line up the mating marks to the yellow links, as shown.

KBIA0115E

11. Pull the timing chain guide out between the camshaft sprockets through front cover. L

12. Line up the mating marks on camshaft sprockets with the yellow links in the timing chain, and paint an indelible mating mark on the sprocket and timing chain link plate. CAUTION: Do not rotate the crankshaft or camshaft while the timing chain is removed. It causes interference between valve and piston. NOTE: Chain tension holding work is not necessary. Crankshaft sprocket and timing chain do not disconnect structurally while front cover is attached. 13. Push in the tensioner plunger and hold. Insert a stopper pin into the hole on tensioner body to hold the chain tensioner. Remove the timing chain tensioner. â&#x2014;? Use a wire with 0.5 mm (0.02 in) diameter for a stopper pin.

KBIA0048E

Revision: September 2005

EM-37

2006 Frontier

CAMSHAFT [QR] 14. Secure the hexagonal part of camshaft with a suitable tool. Loosen the camshaft sprocket bolts and remove the camshaft sprockets.

KBIA0049E

15. Loosen the camshaft bracket bolts in the order as shown, and remove the camshaft brackets and camshafts. ● Remove No.1 camshaft bracket by slightly tapping it with a rubber mallet. ● Note positions, and set them aside in the order removed. 16. Remove the valve lifters. ● Note positions, and set them aside in the order removed.

WBIA0028E

INSPECTION AFTER REMOVAL Camshaft Runout 1.

2. 3.

Put V-block on a precise flat table, and support No. 2 and 5 journals of camshaft. CAUTION: Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations. Set a dial indicator vertically to No. 3 journal. Turn camshaft to one direction with hands, and measure the camshaft runout on the dial indicator. (Total indicator reading) Standard: Less than 0.02 mm (0.0008 in).

PBIC2499E

If out of the standard, replace camshaft.

Camshaft Cam Height 1.

Measure the camshaft cam height with a micrometer. Standard: Intake : 45.015 - 45.205 mm (1.7722 - 1.7797 in) Exhaust : 43.975 - 44.165 mm (1.7313 - 1.7388 in) Cam wear limit : 0.2 mm (0.008 in)

If wear is beyond the limit, replace camshaft. PBIC0039E

Revision: September 2005

EM-38

2006 Frontier

CAMSHAFT [QR] Camshaft Journal Oil Clearance A

CAMSHAFT JOURNAL DIAMETER Measure the outer diameter of camshaft journal with a micrometer. Standard: No. 1 : 27.935 - 27.955 mm (1.0998 - 1.1006 in) No. 2, 3, 4, 5 : 23.435 - 23.455 mm (0.9226 - 0.9234 in)

D PBIC0040E

CAMSHAFT BRACKET INNER DIAMETER ● Tighten camshaft bracket bolts with the specified torque. Refer to EM-41, "INSTALLATION" for the tightening procedure. ● Measure inner diameter “A” of camshaft bracket with a bore gauge. Standard: No. 1 No. 2, 3, 4, 5

: 28.000 - 28.021 mm (1.1024 - 1.1032 in) : 23.500 - 23.521 mm (0.9252 - 0.9260 in)

PBIC1645E

CAMSHAFT JOURNAL OIL CLEARANCE ● (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter) Standard ●

: 0.045 - 0.086 mm (0.0018 - 0.0034 in)

If out of the standard, replace either or both camshaft and cylinder head. NOTE: Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder head. Replace whole cylinder head assembly.

Camshaft End Play 1. 2.

Install camshaft in cylinder head. Refer to EM-41, "INSTALLATION" for tightening procedure. Install a dial indicator in thrust direction on front end of camshaft. Measure the camshaft end play on the dial indicator when camshaft is moved forward/backward (in direction to axis). Standard

: 0.115 - 0.188 mm (0.0045 - 0.0074 in)

PBIC2446E

Revision: September 2005

EM-39

2006 Frontier

CAMSHAFT [QR] ●

–

Measure the following parts if out of the standard. Dimension “A” for camshaft No. 1 journal Standard

–

Dimension “B” for cylinder head No. 1 journal bearing Standard

●

: 25.800 - 25.848 mm (1.0157 - 1.0176 in)

: 25.660 - 25.685 mm (1.0102 - 1.0112 in)

Refer to the standards above, and then replace camshaft and/ or cylinder head. KBIA2426J

Camshaft Sprocket Runout 1.

Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft. CAUTION: Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations. Measure the camshaft sprocket runout with a dial indicator. (Total indicator reading) Limit

●

: 0.15 mm (0.0059 in)

If it exceeds the limit, replace camshaft sprocket.

PBIC0930E

Valve Lifter Check if surface of valve lifter has any wear or cracks. ● If anything above is found, replace valve lifter. Refer to EM-103, "Valve Clearance" .

KBIA0182E

Revision: September 2005

EM-40

2006 Frontier

CAMSHAFT [QR] Valve Lifter Clearance A

VALVE LIFTER OUTER DIAMETER ● Measure the outer diameter of valve lifter with a micrometer. Standard

: 33.965 - 33.980 mm (1.3372 - 1.3378 in)

D JEM798G

VALVE LIFTER HOLE DIAMETER Measure the diameter of valve lifter hole of cylinder head with an inside micrometer. Standard

: 34.000 - 34.021 mm (1.3386 - 1.3394 in)

H PBIC0043E

VALVE LIFTER CLEARANCE ● (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter) Standard ●

: 0.020 - 0.056 mm (0.0008 - 0.0022 in)

If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head. K

INSTALLATION 1.

Install valve lifters. Install them in the original positions. Install camshafts. ● Distinction between intake and exhaust camshafts is performed with the different shapes of rear end. ●

Intake Exhaust

: Signal plate shape for camshaft position sensor (PHASE) : Cone end shape

KBIA0246E

Revision: September 2005

EM-41

2006 Frontier

CAMSHAFT [QR] ●

Install camshafts so that camshaft dowel pins on the front side are positioned as shown.

KBIA0051E

3. a. b.

Install camshaft brackets with the following procedure: Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Install camshaft brackets (No. 2 to 5) aligning the identification marks on upper surface as shown. NOTE: Install so that identification mark can be correctly read when viewed from the exhaust side.

SBIA0256E

c. i.

Install camshaft bracket (No. 1) with the following procedure: Apply liquid gasket to camshaft bracket (No. 1) as shown. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" . CAUTION: After installation, be sure to wipe off any excessive liquid gasket leaking from part “A”.

PBIC2579E

ii.

Apply liquid gasket to camshaft bracket (No. 1) contact surface on the front cover backside. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" . ● Apply liquid gasket to the outside of bolt hole on front cover.

SBIA0258E

Revision: September 2005

EM-42

2006 Frontier

CAMSHAFT [QR] iii. Locate camshaft bracket (No. 1) near installation position, and install it without disturbing the liquid gasket applied to the surfaces.

C PBIC2746E

Tighten bolts of camshaft brackets in the following steps, in numerical order as shown. Step 1 (bolts 9 - 11) : 2.0 N·m (0.2 kg-m, 17 in-lb) Step 2 (bolts 1 - 8) : 2.0 N·m (0.2 kg-m, 17 in-lb) Step 3 (bolts 1 - 11) : 5.9 N·m (0.6 kg-m, 52 in-lb) Step 4 (bolts 1 - 11) : 10.4 N·m (1.1 kg-m, 92 in-lb)

CAUTION: After tightening bolts of camshaft brackets, be sure to wipe off excessive liquid gasket from the parts. 5. Install camshaft position sensor (PHASE). SBIA0255E 6. Install camshaft sprockets. ● Install them by aligning the mating marks on each camshaft sprocket with the paint marks on the timing chain link plates during removal. CAUTION: ● Aligned mating marks could slip. Therefore, after matching them, hold the timing chain in place by hand. ● Before and after installing chain tensioner, make sure again that mating marks have not slipped. NOTE: Before installation of chain tensioner, it is possible to re-match PBIC2351E the marks on timing chain with the ones on each sprocket. 7. Install chain tensioner. CAUTION: After installation, pull the stopper pin off completely, and make sure that chain tensioner plunger is released. 8. Install chain guide. 9. Install oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control cover. 10. Install O-ring to front cover. 11. Apply liquid gasket using Tool to intake valve timing control cover as shown. Tool number

: WS39930000 (

—

)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" .

SBIA0260E

Revision: September 2005

EM-43

2006 Frontier

CAMSHAFT [QR] 12. Tighten bolts in numerical order as shown.

KBIA0085E

13. 14. 15. 16.

Install intake valve timing control solenoid valve to intake valve timing control cover if removed. Connect ground cables, and install harness clip. Check and adjust valve clearance. Refer toEM-103, "Valve Clearance" . Installation is in the reverse order of removal after this step. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after the engine start. However, this is normal. Noise will stop after hydraulic pressure rises.

INSPECTION AFTER INSTALLATION Inspection of Camshaft Sprocket (INT) Oil Groove CAUTION: ● Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-II and it is directed according to inspection procedure of EC section. Refer to EC-70, "DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS" . ● Check when the engine is cold so as to prevent burns from any splashing engine oil. 1. Check the engine oil level. Refer to LU-6, "ENGINE OIL LEVEL" . 2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. a. Release fuel pressure. Refer to EC-86, "FUEL PRESSURE RELEASE" . b. Disconnect ignition coil and injector harness connectors. c. Remove drive belt. Refer to EM-14, "DRIVE BELTS" . 3. Remove intake valve timing control solenoid valve. Refer to EM-36, "REMOVAL" . 4. Crank the engine, and then make sure that engine oil comes out from intake valve timing control cover oil hole. End crank after checking. WARNING: Be careful not to touch rotating parts (drive belt, idler pulley, and crankshaft pulley, etc.). CAUTION: Engine oil may squirt from intake valve timing control solenoid valve installation hole during cranking. Use a shop cloth to prevent the engine components and the vehicle. Do PBIC2723E not allow engine oil to get on rubber components such as drive belt or engine mount insulators. Immediately wipe off any splashed engine oil. ● Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not come out from intake valve timing control cover oil hole. Refer to LU-4, "Lubrication Circuit" . 5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging. ● Clean oil groove if necessary. Refer to LU-4, "Lubrication Circuit" . 6. After inspection, install removed parts.

Revision: September 2005

EM-44

2006 Frontier

CAMSHAFT [QR]

Valve Clearance

EBS00NI1

INSPECTION

Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if there is unusual engine conditions regarding valve clearance. EM 1. Remove rocker cover. Refer to EM-34, "REMOVAL" . 2. Remove undercover. 3. Remove radiator shroud (lower). Refer to CO-15, "REMOVAL" . C 4. Measure the valve clearance with the following procedure: a. Set No. 1 cylinder at TDC of its compression stroke. ● Rotate crankshaft pulley clockwise and align TDC mark to D timing indicator on front cover. E

PBIC3015E

●

At the same time, make sure that both intake and exhaust cam noses of No. 1 cylinder face outside as shown. If they do not face outside, rotate crankshaft pulley once more (360° degrees) and align as shown.

J KBIA0400J

Use a feeler gauge, measure the clearance between valve lifter and camshaft.

SEM139D

Valve clearance: Unit: mm (in) Cold

Hot * (reference data)

Intake

0.24 - 0.32 (0.009 - 0.013)

0.304 - 0.416 (0.012 - 0.016)

Exhaust

0.26 - 0.34 (0.010 - 0.013)

0.308 - 0.432 (0.012 - 0.017)

*:Approximately 80°C (176°F)

Revision: September 2005

EM-45

2006 Frontier

CAMSHAFT [QR] ●

●

By referring to the figure, measure the valve clearances at locations marked “×” as shown in the table below (locations indicated with black arrow in the figure) with a feeler gauge. No. 1 cylinder compression TDC

Measuring position No. 1 cylinder at compression TDC

No. 1 CYL.

INT

EXH

No. 2 CYL.

No. 3 CYL.

No. 4 CYL.

× ×

PBIC3017E

Rotate crankshaft pulley one revolution (360° degrees) and align TDC mark to timing indicator on front cover.

PBIC3015E

●

By referring to the figure, measure the valve clearance at locations marked “×” as shown in the table below (locations indicated with black arrow in the figure) with a feeler gauge. No. 4 cylinder compression TDC

Measuring position No. 4 cylinder at compression TDC

No. 1 CYL.

No. 2 CYL.

INT EXH

No. 3 CYL.

No. 4 CYL.

PBIC3026E

If out of standard, perform adjustment. Refer to EM-46, "ADJUSTMENT" .

ADJUSTMENT ●

1. 2. 3.

Perform adjustment depending on selected head thickness of valve lifter. Remove camshaft. Refer to EM-36, "REMOVAL" . Remove valve lifters at the locations that are out of the standard. Measure the center thickness of the removed valve lifters with a micrometer.

KBIA0057E

Use the equation below to calculate valve lifter thickness for replacement. Valve lifter thickness calculation: t = t1 + (C1 – C2 ) t = Valve lifter thickness to be replaced = Removed valve lifter thickness t1

Revision: September 2005

EM-46

2006 Frontier

CAMSHAFT [QR] C1 C2

●

= Measured valve clearance = Standard valve clearance: Intake : 0.28 mm (0.011 in) Exhaust : 0.30 mm (0.012 in)

Thickness of new valve lifter can be identified by stamp mark on the reverse side (inside the cylinder). Stamp mark “696” indicates 6.96 mm (0.2740 in) in thickness.

E KBIA0119E

NOTE: Available thickness of valve lifter: 26 sizes range 6.96 to 7.46 mm (0.2740 to 0.2937 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-104, "Available Valve Lifter" . 5. Install the selected valve lifter. 6. Install camshaft. Refer to EM-41, "INSTALLATION" . 7. Manually rotate crankshaft pulley a few rotations. 8. Make sure that valve clearances for cold engine are within specifications by referring to the specified values. Refer to EM-45, "INSPECTION" . 9. Installation of the remaining components is in reverse order of removal. 10. Warm up the engine, and check for unusual noise and vibration.

Revision: September 2005

EM-47

2006 Frontier

TIMING CHAIN [QR]

TIMING CHAIN Removal and Installation

PFP:13028 EBS00NI2

WBIA0652E

O-ring

Camshaft sprocket (INT)

Camshaft sprocket (EXH)

Chain tensioner

Spring

Chain tensioner plunger

Timing chain slack guide

Timing chain

Front cover

10. Chain guide

Intake valve timing control solenoid 11. valve

12. Intake valve timing control cover

13. Oil ring

14. Front oil seal

15. Crankshaft pulley

16. Crankshaft pulley bolt

17. Crankshaft sprocket

18. Spacer

19. Balancer unit timing chain tensioner

20. Timing chain tension guide

21. Balancer unit

22. Balancer unit sprocket

23. Balancer unit timing chain

Revision: September 2005

EM-48

2006 Frontier

TIMING CHAIN [QR] REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Release the fuel pressure. Refer to EC-86, "FUEL PRESSURE RELEASE" . Remove the air cleaner and air duct assembly. Refer to EM-16, "REMOVAL" . Remove the spark plugs. Refer to EM-27, "REMOVAL" . Remove the rocker cover. Refer toEM-34, "REMOVAL" . Remove the coolant overflow reservoir tank. Remove the auxiliary drive belt auto-tensioner. Refer to EM-15, "REMOVAL" . Remove the generator. Refer to SC-37, "REMOVAL" . Remove the strut tower brace. Refer to FSU-5, "Components" . Dismount and position aside the A/C compressor with the piping attached. Dismount and position aside the power steering pump and reservoir tank with the piping attached. Remove the upper and lower oil pan, and oil strainer. Refer to EM-23, "REMOVAL" . Remove IVT control cover bolts in the order as shown. Remove the IVT control cover by cutting the sealant using Tool. Tool number

: KV10111100 (J-37228)

14. Pull chain guide between camshaft sprockets out through front cover. G

KBIA0085E

15. Set the No.1 cylinder at TDC on the compression stroke with the following procedure: a. Rotate the crankshaft pulley clockwise and align the mating marks to the timing indicator on the front cover.

KBIA0190E

b. â&#x2014;?

At the same time, make sure that the mating marks on the camshaft sprockets are lined up as shown. If not lined up, rotate the crankshaft pulley one more turn to line up the mating marks to the positions as shown.

KBIA0115E

Revision: September 2005

EM-49

2006 Frontier

TIMING CHAIN [QR] 16. Remove crankshaft pulley with the following procedure: a. Hold the crankshaft pulley with a suitable tool, then loosen the crankshaft pulley bolt, and pull the pulley out about 10 mm (0.39 in). Remove the crankshaft pulley bolt.

KBIA0077E

Attach a pulley puller in the M6 (0.24 in diameter) thread hole on crankshaft pulley, and remove crankshaft pulley.

KBIA0078E

17. Remove the front cover with the following procedure: a. Loosen the front cover bolts in the order as shown, and remove them. b. Remove the front cover. CAUTION: â&#x2014;? Be careful not to damage the mating surface.

WBIA0032E

18. If the front oil seal needs to be replaced, remove it using a suitable tool.

SEM829E

Revision: September 2005

EM-50

2006 Frontier

TIMING CHAIN [QR] 19. Remove timing chain with the following procedure: a. Push in chain tensioner plunger. Insert a stopper pin into hole on chain tensioner body to secure chain A tensioner plunger and remove chain tensioner. NOTE: EM Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin. C

KBIA0048E

Remove timing chain. CAUTION: Do not rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston. 20. Remove camshaft sprockets. Refer to EM-36, "CAMSHAFT" . 21. Remove timing chain slack guide, timing chain tension guide and spacer.

22. a. b. c.

Remove balancer unit timing chain tensioner with the following procedure: Lift lever up, and release ratchet claw for return proof. Push tensioner sleeve in, and hold it. Matching the hole on lever with the one on body, insert a stopper pin to secure tensioner sleeve. NOTE: Use approximately 1 mm (0.04 in) dia. hard metal pin as a stopper pin. Remove balancer unit timing chain tensioner.

K PBIC3027E

23. Secure the hexagonal portion of the balancer shaft using a suitable tool. Loosen the balancer unit sprocket bolt. 24. Remove balancer unit timing chain, balancer unit sprocket and crankshaft sprocket. NOTE: When removing balancer unit timing chain, remove crankshaft sprocket and balancer unit sprocket at the same time. 25. Loosen mounting bolts in reverse order as shown, and remove balancer unit. CAUTION: Do not disassemble balancer unit. NOTE: Use TORX socket (size E14) for bolts No.1 to 4.

PBIC3028E

Revision: September 2005

EM-51

2006 Frontier

TIMING CHAIN [QR] INSPECTION AFTER REMOVAL Timing Chain Check timing chain for cracks and any excessive wear at the roller links of timing chain. Replace timing chain if necessary.

PBIC0282E

Balancer Unit Bolt Outer Diameter ● ●

Measure outer diameters (“d1”, “d2”) at two positions as shown. If reduction appears in “A” range, regard it as “d2”. Limit (“d1” – “d2”)

●

: 0.15 mm (0.0059 in)

If it exceeds the limit (large difference in dimensions), replace balancer unit bolt with a new one.

PBIC1137E

Balancer Unit Bolt Length Measure balancer unit bolt length. If it exceeds the limit, replace balancer unit bolt with a new one. Limit

: 177.15 mm (6.974 in)

INSTALLATION NOTE: The figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed. 1. Make sure that crankshaft key points straight up.

PBIC3029E

Install O-ring to balancer unit.

Revision: September 2005

EM-52

2006 Frontier

TIMING CHAIN [QR] 3.

Tighten bolts in numerical order as shown with the following procedure to install balancer unit, using Tool. Tool number

: KV10112100 (BT8653-A)

CAUTION: If bolts are re-used, check their outer diameter before installation. Refer to EM-52, "Balancer Unit Bolt Outer Diameter" . CAUTION: ● Check tightening angle using Tool or a protractor. Do not make judgment by visual check alone. ● In step 3, loosen bolts in reverse order as shown. NOTE: Apply new engine oil to threads and seat surfaces of bolts. Balancer bolt torque Step 1 bolts 1 - 4 Step 2 bolts 1 - 4 Step 3 bolts 1 - 4 Step 4 bolts 1 - 4 Step 5 bolts 1 - 4 Step 6 bolts 5 - 6

C PBIC3028E

: 48.1 N·m (4.9 kg-m, 35 ft-lb) : 100° clockwise : 0 N·m (0 kg-m, 0 ft-lb) : 48.1 N·m (4.9 kg-m, 35 ft-lb) : 100° clockwise : 30.1 N·m (3.1 kg-m, 22 ft-lb)

G PBIC3030E

Install crankshaft sprocket, balancer unit sprocket and balancer unit timing chain. ● Make sure that crankshaft sprocket is positioned with mating marks on cylinder block and crankshaft sprocket meeting at the top. ● Install it by aligning mating marks on each sprocket and balancer unit timing chain. ● Secure the hexagonal portion of the balancer shaft using a suitable tool. Tighten the balancer unit sprocket bolt to the specified torque. PBIC2183E NOTE: Install crankshaft sprocket, balancer unit sprocket and balancer unit timing chain at the same time.

Install balancer unit timing chain tensioner. ● After installation, make sure the mating marks have not slipped, then remove stopper pin and release tensioner sleeve.

PBIC3032E

Revision: September 2005

EM-53

2006 Frontier

TIMING CHAIN [QR] 6.

Install timing chain and related parts. ● Install by aligning mating marks on each sprocket and timing chain. ● Before and after installing chain tensioner, check again to make sure that mating marks have not slipped. ● After installing chain tensioner, remove stopper pin, and make sure that tensioner moves freely. CAUTION: ● For the following note, after the mating marks are aligned, keep them aligned by holding them with a hand. ● To avoid skipped teeth, do not rotate crankshaft and camshaft until front cover is installed. NOTE: Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for that on each sprocket for alignment.

PBIC3029E

7. 8. 9.

Install front oil seal to front cover. Refer to EM-57, "Removal and Installation of Front Oil Seal" . Install O-rings to cylinder head and cylinder block. Apply a continuous bead of liquid gasket with the tube presser to front cover as shown, using Tool. Tool number

: WS39930000 (

—

)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" . NOTE: Application instruction differs depending on the position. Detail of A Detail of B

Detail of C

: Cross over the start of the application and the end. : Apply liquid gasket outside of bolt holes. (For all bolt holes other than B, apply to the inside.) : Between here only, apply 4.5 - 5.5 mm (0.177 - 0.217 in) dia.

PBIC3031E

10. Make sure that mating marks of timing chain and each sprocket are still aligned. Then install front cover. CAUTION: Be careful not to damage front oil seal by interference with front end of crankshaft.

Revision: September 2005

EM-54

2006 Frontier

TIMING CHAIN [QR] 11. Tighten bolts in numerical order as shown. ● Refer to the following for locating M6 bolts. : 45 mm (1.77 in) : 20 mm (0.79 in) ●

Bolt position : 5, 10, 14, 17 : Except the above (Except 1 to 4)

Tighten bolts to the specified torque. C

M6 bolts M10 bolts

12.8 N·m (1.3 kg-m, 9 ft-lb) 49.0 N·m (5.0 kg-m, 36 ft-lb) D

12. After all bolts are tightened, retighten them to the specified torque in numerical order as shown. CAUTION: Be sure to wipe off any excessive liquid gasket leaking to surface for fitting oil pan.

G KBIA0083E

13. Install chain guide between camshaft sprockets. 14. Install oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control cover. 15. Install O-ring to front cover. 16. Apply a continuous bead of liquid gasket using Tool to intake valve timing control cover as shown. Tool number

: WS39930000 (

—

)

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" . K

L SBIA0260E

17. Tighten bolts in numerical order as shown. M

KBIA0085E

18. Install intake valve timing control solenoid valve to intake valve timing control cover if removed. 19. Connect ground cables, and install harness clip. 20. Insert crankshaft pulley by aligning with crankshaft key. ● When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). CAUTION: Install protecting front oil seal lip section from any damage. Revision: September 2005

EM-55

2006 Frontier

TIMING CHAIN [QR] 21. Tighten crankshaft pulley bolt using Tool. Tool number

: KV10112100 (BT-8653-A)

Secure crankshaft pulley using suitable tool, and tighten crankshaft pulley bolt. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. Tighten crankshaft pulley bolt. ●

a. b.

: 42.1 N·m (4.3 kg-m, 31 ft-lb) c. d.

Put a paint mark on crankshaft pulley, mating with any one of six easy to recognize angle marks on bolt flange. Turn another 60° degrees clockwise (angle tightening). ● Check the tightening angle with movement of one angle mark.

SEM751G

22. Install all removed parts in the reverse order of removal.

INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluid leaks, lubricates leak and exhaust gases leak. ● Before starting the engine, check oil fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to MA-11, "QR25DE" . ● Use procedures below to check for fuel leakage. – Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. – Start the engine. With the engine speed increased, check again for fuel leakage at connection points. ● Run the engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after the engine start. However, this is normal. Noise will stop after hydraulic pressure rises. ● Warm up the engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/ fluids including engine oil and engine coolant. ● Bleed air from lines and hoses of applicable lines, such as in cooling system. ● After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary. Summary of the inspection items: Item

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Leakage

—

Leakage

—

Fuel Exhaust gases

* Transmission/transaxle/AT fluid, power steering fluid, brake fluid, etc.

Revision: September 2005

EM-56

2006 Frontier

OIL SEAL [QR]

OIL SEAL Removal and Installation of Valve Oil Seal

PFP:12279

A EBS00NI3

REMOVAL 1. 2. 3. 4. 5.

Remove fan shroud (lower). Refer to CO-15, "RADIATOR" . EM Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve from dropping into cylinder. Remove camshafts. Refer to EM-36, "CAMSHAFT" . C Remove valve lifters. Refer to EM-36, "CAMSHAFT" . Remove valve collet, valve spring retainer and valve spring using Tool. D Tool numbers : KV10116200 (J-26336-B) : KV10115900 (J-26336-20) E CAUTION: When working, be careful not to damage valve lifter holes. F WBIA0477E

Remove valve spring retainer and valve spring. CAUTION: Do not remove valve spring seat from valve spring. Remove valve oil seal using Tool. Tool numbers

: KV10107902 (J-38959) I

K WBIA0478E

INSTALLATION 1. 2.

Apply new engine oil to valve oil seal joint surface and seal lip. Press in valve oil seal to the height “H” as shown using Tool. Tool numbers

: KV10107902 (J-38959)

WBIA0653E

Installation of the remaining components is in the reverse order of removal.

Removal and Installation of Front Oil Seal

EBS00NI4

REMOVAL 1. 2. 3. 4.

Remove engine undercover. Remove fan shroud (lower); Refer to CO-18, "COOLING FAN" Remove cooing fan; Refer to CO-18, "COOLING FAN" . Remove drive belt; Refer to EM-14, "DRIVE BELTS" .

Revision: September 2005

EM-57

2006 Frontier

OIL SEAL [QR] 5. 6.

Remove crankshaft pulley; Refer to EM-48, "TIMING CHAIN" . Remove front oil seal using a suitable tool. CAUTION: Be careful not to damage front cover and crankshaft.

SEM829E

INSTALLATION 1. 2.

Apply new engine oil to new front oil seal joint surface and seal lip. Install front oil seal so that each seal lip is oriented as shown.

SEM715A

●

Press-fit front oil seal until it is flush with front end surface of front cover using suitable tool. CAUTION: ● Be careful not to damage front cover and crankshaft. ● Press-fit oil seal straight to avoid causing burrs or tilting.

PBIC3033E

Installation of the remaining components is in the reverse order of removal.

Removal and Installation of Rear Oil Seal

EBS00NI5

REMOVAL 1.

2. 3. 4.

Remove transmission assembly. Refer to MT-16, "REMOVAL" (M/T models), MT-67, "REMOVAL" (2WD models), MT-69, "REMOVAL" (4WD models) or AT-252, "REMOVAL" (2WD), AT-254, "REMOVAL" (4WD) (A/T models). Remove clutch cover and clutch disk (M/T models). Refer to CL-18, "REMOVAL" . Remove drive plate (A/T models) or flywheel (M/T models) with power tool. Refer to EM-75, "CYLINDER BLOCK" . Remove rear oil seal with a suitable tool. CAUTION: Be careful not to damage crankshaft and cylinder block.

INSTALLATION 1.

Apply new engine oil to new rear oil seal joint surface and seal lip.

Revision: September 2005

EM-58

2006 Frontier

OIL SEAL [QR] 2.

Install rear oil seal so that each seal lip is oriented as shown. A

C SEM715A

D ●

Press in rear oil seal to the position as shown. E

G WBIA0654E

●

Press-fit rear oil seal using a suitable drift [outside diameter 102 mm (4.02 in), inside diameter 86 mm (3.39 in)]. CAUTION: ● Be careful not to damage crankshaft and cylinder block. ● Press-fit oil seal straight to avoid causing burrs or tilting. ● Do not touch grease applied onto oil seal lip.

SBIA0280E

Installation of the remaining components is in the reverse order of removal. L

Revision: September 2005

EM-59

2006 Frontier

CYLINDER HEAD [QR]

CYLINDER HEAD On-Vehicle Service

PFP:11041 EBS00NI6

CHECKING COMPRESSION PRESSURE 1. 2. 3.

Warm up engine thoroughly. Then, stop it. Release fuel pressure. Refer to EC-689, "FUEL PRESSURE RELEASE" . Disconnect fuel pump fuse to avoid fuel injection during measurement.

BBIA0534E

4. 5. 6.

Remove spark plug from each cylinder. Refer to EM-27, "SPARK PLUG (PLATINUM-TIPPED TYPE)" . Connect an engine tachometer (not required in use of CONSULT-II). Install a compression tester with an adapter (commercial service tool) onto spark plug hole.

LBIA0448E

●

Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal.

SBIA0533E

With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each cylinder. Compression pressure: Unit: kPa (kg/cm2 , psi) /rpm Standard

Minimum

1,304 (13.3, 189) / 250

1,108 (11.3, 161) / 250

Differential limit between cylinders 100 (1.0, 14) / 250

CAUTION: Always use fully a changed battery to obtain the specified engine speed. ● If the engine speed is out of the specified range, check battery liquid for proper gravity. Check engine speed again with normal battery gravity. Revision: September 2005

EM-60

2006 Frontier

CYLINDER HEAD [QR] If compression pressure is below minimum value, check valve clearances and parts associated with combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head A gasket). After the checking, measure the compression pressure again. ● If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. EM ● If the added engine oil improves the compression, piston rings may be worn out or damaged. Check piston rings and replace if necessary. ● If the compression pressure remains at low level despite the addition of engine oil, valves may be malC functioning. Check valves for damage. Replace valve or valve seat accordingly. ● If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, cylinder head gasket is leaking. In such a case, replace cylin- D der head gasket. 8. After inspection is completed, install removed parts. 9. Start the engine, and confirm that the engine runs smoothly. E 10. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-691, "TROUBLE DIAGNOSIS" . ●

Removal and Installation

EBS00NI7

PBIC3025E

Cylinder head assembly

Cylinder head gasket

Cylinder head bolt

REMOVAL 1. 2.

4. 5. 6. 7. 8.

Release fuel pressure. Refer to EC-689, "FUEL PRESSURE RELEASE" . Drain engine coolant. Refer to CO-11, "DRAINING ENGINE COOLANT" . CAUTION: ● Perform this step when the engine is cold. ● Do not spill engine coolant on drive belt. Drain engine oil; Refer to MA-26, "Changing Engine Oil" . CAUTION: ● Perform this step when the engine is cold. ● Do not spill engine oil on drive belt. Intake manifold and fuel tube assembly; Refer to EM-18, "INTAKE MANIFOLD" . Remove fuel injector and fuel tube assembly; Refer to EM-29, "FUEL INJECTOR AND FUEL TUBE" . Exhaust manifold and three way catalyst assembly; Refer to EM-21, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . Remove water outlet; Refer to CO-27, "REMOVAL" . Remove heater outlet; Refer to CO-27, "WATER OUTLET AND WATER PIPING" .

Revision: September 2005

EM-61

2006 Frontier

CYLINDER HEAD [QR] NOTE: Can be removed and installed even when assembled with cylinder head. 9. Remove front cover and timing chain. Refer to EM-48, "TIMING CHAIN" . 10. Remove camshafts. Refer to EM-36, "CAMSHAFT" . 11. Remove cylinder head loosening bolts in reverse order as shown using power tool. ● Using the cylinder head bolt wrench (commercial service tool: J-24239-01), loosen cylinder head bolts.

KBIA0058E

12. Remove cylinder head gasket.

INSPECTION AFTER REMOVAL Cylinder Head Bolts Outer Diameter ●

Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between “d1” and “d2” exceeds the limit, replace them with a new one. Limit (“d1” – “d2”): 0.23 mm (0.0091 in)

●

If reduction of outer diameter appears in a position other than “d2”, use it as “d2” point.

SBIA0269E

Cylinder Head Distortion NOTE: When performing this inspection, cylinder block distortion should be also checking. Refer to EM-95, "CYLINDER BLOCK DISTORTION" . 1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper. CAUTION: Use utmost care not to allow gasket debris to enter passages for engine oil or engine coolant. 2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions. Limit ●

: 0.1 mm (0.004 in)

If it exceeds the limit, replace cylinder head.

PBIC0075E

Revision: September 2005

EM-62

2006 Frontier

CYLINDER HEAD [QR] INSTALLATION 1. 2.

Install new cylinder head gasket. Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown. CAUTION: If cylinder head bolts re-used, check their outer diameters before installation. Refer to EM-62, "Cylinder Head Bolts Outer Diameter" . NOTE: Apply new engine oil to threads and seating surfaces of mounting bolts. Tool number

: KV10112100 (BT8653-A) KBIA0058E

Step a Step b Step c Step d Step e

: 98 N·m (10 kg-m, 72 ft-lb) : Loosen to 0 N·m in the reverse order of tightening. : 39.2 N·m (4.0 kg-m, 29 ft-lb) : 75° clockwise : 75° clockwise

WBIA0617E

Installation of the remaining components is in reverse order of removal. I

Revision: September 2005

EM-63

2006 Frontier

CYLINDER HEAD [QR] Summary of the inspection items: Before starting engine

Engine running

After engine stopped

Engine coolant

Item

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Leakage

—

Leakage

—

Fuel Exhaust gases

* Transmission/transaxle/AT fluid, power steering fluid, brake fluid, etc.

Disassembly and Assembly

EBS00NI8

PBIC3024E

Valve collet

Valve spring retainer

Valve spring (with valve spring seat)

Valve oil seal

Valve guide

Cylinder head

Valve seat

Valve (INT)

Valve (EXH)

10. Spark plug tube

11. Spark plug

DISASSEMBLY 1. 2.

Remove spark plug using suitable tool. Remove valve lifter. ● Identify installation positions, and store them without mixing them up.

Revision: September 2005

EM-64

2006 Frontier

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