Page 1

QUICK REFERENCE INDEX Edition: October 2003 Revision: October2003 Publication No. SM4E-1D22U0

A GENERAL INFORMATION

GI

General Information

B ENGINE

EM

Engine Mechanical

LU

Engine Lubrication System

CO

Engine Cooling System

EC

Engine Control System

FL

Fuel System

EX

Exhaust System

ACC

C

TRANSMISSION/ TRANSAXLE

D DRIVELINE/AXLE

E SUSPENSION

F BRAKES

Accelerator Control System

CL

Clutch

MT

Manual Transmission

AT

Automatic Transmission

TF

Transfer

PR

Propeller Shaft

FFD

Front Final Drive

RFD

Rear Final Drive

FAX

Front Axle

RAX

Rear Axle

FSU

Front Suspension

RSU

Rear Suspension

WT

Road Wheels & Tires

BR

Brake System

PB

Parking Brake System

BRC

Brake Control System

G STEERING

PS

Power Steering System

H RESTRAINTS

SB

Seat Belts

SRS

I

BODY

J AIR CONDITIONER K ELECTRICAL

Supplemental Restraint System (SRS)

BL

Body, Lock & Security System

GW

Glasses, Window System & Mirrors

RF

Roof

EI

Exterior & Interior

IP

Instrument Panel

SE

Seat

MTC

Manual Air Conditioner

SC

Starting & Charging System

LT

Lighting System

DI

Driver Information System

WW

Wiper, Washer & Horn

BCS

Body Control System

AV ACS

Audio Visual & Telephone System Auto Cruise Control System

PG

Power Supply, Ground & Circuit Elements

L MAINTENANCE

MA

Maintenance

M INDEX

IDX

Alphabetical Index

© 2003 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 2004 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 vehicle’s safety will be jeopardized by the service method selected.

-2


QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH KA24DE ENGINE

2004

QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH KA24DE ENGINE PFP:00027

Engine Tune-Up Data

ELS000OU

Engine

KA24DE

Classification

Gasoline

Cylinder arrangement

In-line 4 2,389 cm3 (145.78 cu in)

Displacement Bore and stroke

89 x 96 mm (3.50 x 3.78 in)

Valve arrangement

DOHC

Firing order

1-3-4-2

Number of piston rings

Compression

2

Oil

1

Number of main bearings

5

Compression ratio

9.2 2

Cap relief pressure

78 - 98 (0.8 - 1.0, 11 - 14)

Standard kPa (kg/cm , psi) Limit kPa (kg/cm2 , psi)

59 (0.6, 9)

Leakage test pressure kPa (kg/cm2 , psi)

157 (1.6, 23) 29.4 - 39.2 N·m (3.0 - 4.0 kg-m, 21.69 28.91 lb-ft)

Oil drain plug tightening specification

Idle Speed and Ignition Timing Base idle speed*1

No-load*3 (in “P” or “N” position)

750±50

Target idle speed*2

rpm rpm

No-load*3 (in “P” or “N” position)

800±50

Air conditioner: ON

rpm

In “P” or “N” position

875 or more

In “P” or “N” position

20°±2° BTDC

Ignition timing*1

*1: Throttle position sensor harness connector disconnected or using CONSULT-II “WORK SUPPORT” mode *2: Throttle position sensor harness connector connected *3: Under the following conditions: ●

Air conditioner switch: OFF

Electrical load: OFF (Lights, heater fan & rear window defogger)

Steering wheel: Kept in straight-ahead position

Drive Belt Deflection and Tension Deflection adjustment

Unit: mm (in)

Used belt Limit

After adjustment

Generator

17 (0.67)

10 - 12 (0.39 0.47)

Air conditioner compressor

16 (0.63)

Power steering oil pump

17 (0.67)

Applied pushing force

Tension adjustment

*1 Unit: N (kg, lb)

Used belt

New belt

New belt

Limit

After adjustment

8 - 10 (0.31 0.39)

222.4 (22.7, 50)

355.8 - 444.8 (36.3 - 45.4, 80 100)

489.3 - 578.2 (49.9 - 59.0, 110 - 130)

10 - 12 (0.39 0.47)

8 - 10 (0.31 0.39)

200.2 (20.4, 45)

355.8 - 444.8 (36.3 - 45.4, 80 100)

489.3 - 578.2 (49.9 - 59.0, 110 - 130)

10 - 13 (0.39 0.51)

8 - 10 (0.31 0.39)

222.4 (22.7, 50)

355.8 - 444.8 (36.3 - 45.4, 80 100)

489.3 - 578.2 (49.9 - 59.0, 110 - 130)

98 N (10 kg, 22 lb)

*1: If belt tension gauge cannot be installed at check point shown, check belt tension at a different location on the belt.


QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH KA24DE ENGINE 2004 Spark Plugs (Double Platinum Tipped) Make

NGK

Standard type

PFR5G-11

Cold type

PFR6G-11

Plug gap

Nominal 1.1 mm (0.043 in)

Spark plug tightening specification

20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

Wheel Bearing (Front) Wheel bearing axial end play

ELS000QB

mm (in)

0 (0) Tightening torque

Wheel bearing lock nut

Return angle

N·m (kg-m, ft-lb)

degree

At wheel hub bolt With new grease seal

Wheel bearing starting torque

With used grease seal

34 - 39 (3.5 - 4.0, 25 - 29) 45° - 60°

N (kg, lb) N (kg, lb)

9.8 - 28.4 (1.0 - 2.9, 2.2 - 6.4) 9.8 - 23.5 (1.0 - 2.4, 2.2 - 5.3)

Clutch Pedal

ELS000QC

Unit: mm (in) Clearance between pedal stopper bracket and clutch interlock switch (with clutch pedal fully depressed.)

0.1 - 1.0 (0.004 - 0.039)

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

Front Wheel Alignment (Unladen*1) Camber Degree minute (Decimal degree)

ELS000Q7

Minimum

−0°05′ (−0.08°)

Nominal

0°25′ (0.42°)

Maximum

0°55′ (0.92°)

Left and right difference

Caster Degree minute (Decimal degree)

Minimum

0°06′ (0.10°)

Nominal

0°36′ (0.60°)

Maximum

1°06′ (1.10°)

Left and right difference Kingpin inclination Degree minute (Decimal degree)

8°35′ (8.58°)

Nominal

9°05′ (9.08°)

Maximum

9°35′ (9.58°)

Radial tire

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

Wheel turning angle

Radial tire

Inside Degree minute (Decimal degree) Full turn*2 Outside Degree minute (Decimal degree)

Vehicle posture

Lower arm pivot height

mm (in)

45′ (0.75°) or less

Minimum

Minimum Distance mm (in)

45′ (0.75°) or less

2 (0.08)

Nominal

3 (0.12)

Maximum

4 (0.16)

Minimum

11′ (0.18°)

Nominal

16′ (0.27°)

Maximum

20′ (0.33°) P225/70R15

Minimum

31°48′ (31.80°)

Nominal

33°48′ (33.80°)

Maximum

33°48′ (33.80°)

Minimum

28°36′ (28.60°)

Nominal

30°36′ (30.60°)

Maximum

30°36′ (30.60°) 115 - 119 (4.53 - 4.69)


QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH KA24DE ENGINE 2004 *1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.

Rear Wheel Alignment (Unladen*)

ELS000Q8

−1°45′ (−1.75°)

Minimum Camber Degree minute (decimal degree)

Distance mm (in) Total toe-in Angle (left plus right) Degree minute (decimal degree)

Nominal

−1°00′ (−1.00°)

Maximum

−0°15′ (−0.25°)

Minimum

−3 (−0.12)

Nominal

1 (0.04)

Maximum

5 (0.20)

Minimum

−16′ (−0.27°)

Nominal

5′30″ (0.09°)

Maximum

26′ (0.43°)

*: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

Brake

ELS000P4

Unit: mm (in) Brake model

CL28VD

Cylinder bore diameter × number of pistons Front brake

Pad Length × width × thickness

146.6 x 48.5 x 10 (5.77 x 1.909 x 0.39)

Rotor outer diameter × thickness

260 x 26 (10.2 x 1.02)

Brake model

LT26B

Cylinder bore diameter Rear brake

Lining length × width × thickness Drum inner diameter

Master cylinder

42.8 (1.685) x 2

22.22 (7/8) 249.6 x 40 x 5.5 (9.83 x 1.57 x 0.217 260.0 (10.23)

Bore diameter

25.40 (1)

Booster model

M195T

Brake booster

Pri: 205 (8.07) Sec: 180 (7.09)

Diaphragm diameter Recommended brake fluid

DOT 3

Disc Brake - Repair Limits Unit: mm (in) Brake model Pad

CL28VD Wear limit minimum thickness Standard pad thickness

2.0 (0.079) 10 (0.39)

Rotor repair limit

Minimum thickness

24.0 (0.945)

Rotor runout

Maximum

0.07 (0.0028)

Rotor thickness variation

Maximum

0.02 (0.0008)

Drum Brake - Repair Limits Unit: mm (in) Brake model Lining wear limit

Drum repair limit

LT26B Minimum thickness

1.5 (0.059)

Standard thickness

5.5 (0.217)

Maximum inner diameter

261.5 (10.30)

Out-of-round limit

0.03 (0.0012)


QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH KA24DE ENGINE 2004

Refill Capacities

ELS000PA

Capacity (Approximate)

Engine oil

Drain and Refill

US measure

Imp measure

Liter

With oil filter

3-3/4 qt

3-1/8 qt

3.5

Without oil filter

3-1/2 qt

2-7/8 qt

3.3

4-1/2 qt

3-3/4 qt

4.1

7-3/4 qt

6-3/8 qt

7.3

Dry engine (Engine overhaul) MT Cooling system (With reservoir)

AT

Manual transmission gear oil (FS5W71C) Differential carrier gear oil Automatic transmission fluid Power steering fluid

C200

7-1/2 qt

6-1/4 qt

7.1

4-1/4 pt

3-1/2 pt

2.0

2-3/8 pt

2-1/4 pt

1.3

8-3/8 qt

7 qt

7.9

30.4-33.8 fl oz

31.7-35.2 fl oz

0.9-1.0


QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH VG33E/ VG33ER ENGINES

2004

QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH VG33E/VG33ER ENGINES PFP:00027 Engine Tune-Up Data

ELS000OP

Engine

VG33E/VG33ER

Classification

Gasoline

Cylinder arrangement

V-6

Displacement

3,275 cm

Bore and stroke

(199.84 cu in)

91.5 x 83 mm (3.602 x 3.27 in)

Valve arrangement

OHC

Firing order

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

Number of piston rings

3

2

Oil

1

Number of main bearings

4 VG33E

8.9:1

Compression ratio VG33ER

8.3:1 2

Cap relief pressure

Standard kPa (kg/cm , psi)

78 - 98 (0.8 - 1.0, 11 - 14)

Limit kPa (kg/cm2 , psi)

59 (0.6, 9)

Leakage test pressure kPa (kg/cm2 , psi)

157 (1.6, 23)

Oil drain plug tightening specification

29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 lb-ft)

Idle Speed and Ignition Timing - VG33E Base idle speed*1

No-load*4 (in “P” or N” position)

700±50 rpm

Target idle speed*2

No-load*4 (in “P” or N” position)

750±50 rpm

Air conditioner: ON

In “P” or N” position

850 rpm or more

Ignition timing*3

In “P” or N” position

10°±2° BTDC

Throttle position sensor idle position

0.15 - 0.85V

*1: Throttle position sensor harness connector disconnected or using CONSULT-II “WORK SUPPORT” mode *2: Throttle position sensor harness connector connected *3: Throttle position sensor harness connector disconnected *4: Under the following conditions: ●

Air conditioner switch: OFF

Electric load: OFF (Lights, heater fan & rear window defogger)

Steering wheel: Kept in straight-ahead position

Idle Speed and Ignition Timing - VG33ER Base idle speed*1

No-load*4 (in “P” or N” position)

700±50 rpm

Target idle speed*2

No-load*4 (in “P” or N” position)

750±50 rpm

Air conditioner: ON

In “P” or N” position

850 rpm or more

Ignition timing*3

In “P” or N” position

10°±2° BTDC

Throttle position sensor idle position

0.15 - 0.85V

*1: Throttle position sensor harness connector disconnected or using CONSULT-II “WORK SUPPORT” mode *2: Throttle position sensor harness connector connected *3: Throttle position sensor harness connector disconnected *4: Under the following conditions: ●

Air conditioner switch: OFF

Electric load: OFF (Lights, heater fan & rear window defogger)

Steering wheel: Kept in straight-ahead position


QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH VG33E/ VG33ER ENGINES 2004 Drive Belt Deflection and Tension Deflection adjustment

Unit: mm (in)

Tension adjustment

Used belt

*1 Unit: N (kg, lb)

Used belt

Limit

After adjustment

Generator

11 (0.43)

7 - 8 (0.24 - 0.31)

Air conditioner compressor VG33E

18 (0.71)

Air conditioner compressor and supercharger VG33ER Power steering oil pump

New belt

New belt

Limit

After adjustment

6 - 7 (0.24 0.28)

226 (23, 51)

554.1 - 642.4 (56.5 - 65.5, 124.6 - 144.4)

671.8 - 760.0 (68.5 - 77.5, 151.0 - 170.9)

12 - 13 (0.47 0.51)

10.5 - 11.5 (0.413 - 0.453)

196 (20, 44)

495.3 - 583.5 (50.5 - 59.5, 111.4 - 131.2)

603.1 - 691.4 (61.5 -70.5, 135.6 - 155.5)

16.5 (0.65)

9.5 - 10.5 (0.374 - 0.413)

8.5-9.5 (0.33 0.37)

294 (30 , 66)

730 - 818 (75.5 83.5, 166.5 184.1)

838 - 926 (85.5 94.5, 188.5 208.4)

15 (0.59)

9.5 - 10.5 (0.374 - 0.413)

8 - 9 (0.31 0.35)

275 (28, 62)

554.1 - 642.4 (56.5 - 65.5, 124.6 - 144.4)

671.8 - 760.0 (68.5 - 77.5, 151.0 - 170.9)

Applied pushing force

98 N (10 kg, 22 lb)

*1: If belt tension gauge cannot be installed at check point shown, check belt tension at a different location on the belt.

Spark plug (VG33E): Description

NGK (Double Platinum Tipped)

Hot type

PFR4G-11

Standard type

PFR5G-11

Cold type

PFR6G-11

Plug gap

Nominal 1.1 mm (0.043 in)

Spark plug tightening specification

20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

Spark plug (VG33ER): Description

NGK (Double Platinum Tipped)

Hot type

PFR5G-11

Standard type

PFR6G-11

Cold type

PFR7G-11

Plug gap

Nominal 1.1 mm (0.043 in)

Spark plug tightening specification

20 - 29 N·m (2.0 - 3.0 kg-m, 14 - 22 ft-lb)

Wheel Bearing (Front)

ELS000QD

2WD MODELS Wheel bearing axial end play

mm (in)

0 (0) Tightening torque

N·m (kg-m, ft-lb)

34 - 39 (3.5 - 4.0, 25 - 29)

Wheel bearing lock nut Return angle Wheel bearing starting torque

degree

At wheel hub bolt With new grease seal With used grease seal

45° - 60° N (kg, lb) N (kg, lb)

9.8 - 28.4 (1.0 - 2.9, 2.2 - 6.4) 9.8 - 23.5 (1.0 - 2.4, 2.2 - 5.3)


QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH VG33E/ VG33ER ENGINES 2004 4WD MODELS Tightening torque

N·m (kg-m, ft-lb)

78 - 98 (8 - 10, 58 - 72)

Retightening torque after loosening wheel bearing lock nut N·m (kg-m, ft-lb) Axial end play

Wheel bearing lock nut

mm (in)

Starting force at wheel hub bolt Turning angle

0 (0) N (kg, lb)

A

degree

Starting force at wheel hub bolt Wheel bearing preload at wheel hub bolt N (kg, lb)

0.5 - 1.5 (0.05 - 0.15, 0.4 - 1.1)

B−A

15° - 30° N (kg, lb)

B 7.06 - 20.99 (0.72 - 2.14, 1.59 - 4.72)

Clutch Pedal

ELS000QE

Unit: mm (in) Clearance between pedal stopper bracket and clutch interlock switch (with clutch pedal fully depressed.)

0.1 - 1.0 (0.004 - 0.039)

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

Front Wheel Alignment (Unladen*1)

ELS000PR

2WD MODELS Camber Degree minute (Decimal degree)

Minimum

0°03′ (0.05°)

Nominal

0°33′ (0.55°)

Maximum

1°03′ (1.05°)

Left and right difference

Caster Degree minute (Decimal degree)

45′ (0.75°) or less

Minimum

2°04′ (2.07°)

Nominal

2°34′ (2.57°)

Maximum

3°04′ (3.07°)

Left and right difference Kingpin inclination Degree minute (Decimal degree)

Distance (A − B) mm (in)

Minimum

10°23′ (10.38°)

Nominal

10°53′ (10.88°)

Maximum

11°23′ (11.38°)

Radial tire

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

Wheel turning angle

Inside Degree minute (Decimal degree) Full turn*2 Outside Degree minute (Decimal degree)

Vehicle posture

Lower arm pivot height (H)

45′ (0.75°) or less

Radial tire

Minimum

3 (0.12)

Nominal

4 (0.16)

Maximum

5 (0.20)

Minimum

15′ (0.25°)

Nominal

20′ (0.33°)

Maximum

25′ (0.42°) VG33E

VG33ER

Minimum

31°00′ (31.00°)

30°48′ (30.80°)

Nominal

33°00′ (33.00°)

32°48′ (32.80°)

Maximum

33°00′ (33.00°)

32°48′ (32.80°)

Minimum

29°00′ (29.00°)

28°42′ (28.70°)

Nominal

31°00′ (31.00°)

30°42′ (30.70°)

Maximum

31°00′ (31.00°)

30°42′ (30.70°)

mm (in)

37.7 - 41.7 (1.484 - 1.642)

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.


QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH VG33E/ VG33ER ENGINES 2004 4WD MODEL VG33E

Camber Degree minute (Decimal degree)

Minimum

0°06′ (0.10°)

0°03′ (0.05°)

Nominal

0°36′ (0.60°)

0°33′ (0.55°)

Maximum

1°06′ (1.10°)

1°03′ (1.05°)

Left and right difference

Caster Degree minute (Decimal degree)

Distance (A − B) mm (in)

1°40′ (1.67°)

2°04′ (2.07°)

Nominal

2°10′ (2.17°)

2°34′ (2.57°)

Maximum

2°40′ (2.67°)

3°04′ (3.07°)

45′ (0.75°) or less

Minimum

10°18′ (10.30°)

Nominal

10°48′ (10.80°)

Maximum

11°18′ (11.30°)

Radial tire

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

45′ (0.75°) or less

Minimum

Left and right difference Kingpin inclination Degree minute (Decimal degree)

Radial tire

Minimum

3 (0.12)

Nominal

4 (0.16)

Maximum

5 (0.20)

Minimum

15′ (0.25°)

Nominal

20′ (0.33°)

Maximum

Wheel turning angle

Vehicle posture

Inside Degree minute (Decimal degree) Full turn*2 Outside Degree minute (Decimal degree) Lower arm pivot height (H)

VG33ER

25′ (0.42°)

Minimum

31°00′ (31.00°)

30°48′ (30.80°)

Nominal

33°00′ (33.00°)

32°48′ (32.80°)

Maximum

33°00′ (33.00°)

32°48′ (32.80°)

Minimum

29°00′ (29.00°)

28°42′ (28.70°)

Nominal

31°00′ (31.00°)

30°42′ (30.70°)

Maximum

31°00′ (31.00°)

30°42′ (30.70°)

45.5 - 49.5 (1.791 1.949)

37.7 - 41.7 (1.484 - 1.642)

mm (in)

*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions. *2: Wheel turning force (at circumference of steering wheel) of 98 to 147 N (10 to 15 kg, 22 to 33 lb) with engine idle.

Rear Wheel Alignment (Unladen*)

ELS000OR

Minimum Camber Degree minute (decimal degree)

Distance mm (in) Total toe-in Angle (left plus right) Degree minute (decimal degree)

−1°45′ (−1.75°)

Nominal

−1°00′ (−1.00°)

Maximum

−0°15′ (−0.25°)

Minimum

−3 (−0.12)

Nominal

1 (0.04)

Maximum

5 (0.20)

Minimum

−16′ (−0.27°)

Nominal

5′30″ (0.09°)

Maximum *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

26′ (0.43°)


QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH VG33E/ VG33ER ENGINES 2004

Brake

ELS000Q9

Unit: mm (in) Brake model

CL33VD

Cylinder bore diameter × number of pistons Front brake

Pad Length × width × thickness

46.4 (1.827) x 2 132.0 x 52.5 x 11 (5.20 x 2.067 x 0.43)

Rotor outer diameter × thickness

283 x 28 (11.4 x 1.10)

Brake model

LT30A

Cylinder bore diameter Rear brake

Lining length × width × thickness

22.22 (7/8) 296 × 50 × 6.1 (11.65 × 1.97 × 0.240)

Drum inner diameter Master cylinder

295.0 (11.61)

Bore diameter

25.40 (1)

Booster model

M230t

Brake booster

Pri: 230 (9.06) Sec: 230 (9.06)

Diaphragm diameter Recommended brake fluid

DOT 3

Disc Brake - Repair Limits Unit: mm (in) Brake model Pad

CL33VD Wear limit minimum thickness

2.0 (0.079)

Standard pad thickness

10 (0.39)

Rotor repair limit

Minimum thickness

26.0 (1.024)

Rotor runout

Maximum

0.07 (0.0028)

Rotor thickness variation

Maximum

0.02 (0.0008)

Drum Brake - Repair Limits Unit: mm (in) Brake model Lining wear limit

Drum repair limit

LT30A Minimum thickness

1.5 (0.059)

Standard thickness

5.8 (0.228)

Maximum inner diameter

296.5 (11.67)

Out-of-round limit

0.03 (0.0012)

Refill Capacities

ELS000QA

Capacity (Approximate)

Engine oil

Drain and refill

US measure

Imp measure

Liter

With oil filter

3-1/2 qt

2-7/8 qt

3.3

Without oil filter

3-1/8 qt

2-5/8 qt

3.0

4 qt

3-3/8 qt

3.8

11-5/8 qt

9-5/8 qt

10.95

2WD

5-7/8 pt

4-7/8 pt

2.8

4WD

10-3/4 pt

9 pt

5.1

Dry engine (Engine overhaul) Cooling system (With reservoir) Manual transmission gear oil (FS5R30A) Transfer fluid (TX10A)

Differential carrier gear oil

2-3/8 qt

2 qt

2.2

Front (4WD) R200A

3-3/4 pt

3-1/8 pt

1.75

Rear H233B

5-7/8 pt

4-7/8 pt

2.8


QUICK REFERENCE CHART: FRONTIER EQUIPPED WITH VG33E/ VG33ER ENGINES 2004 Capacity (Approximate)

Automatic transmission fluid Power steering fluid

US measure

Imp measure

Liter

2WD

8-3/4 qt

7-1/4 qt

8.3

4WD

9 qt

7-1/2 qt

8.5

33.8-37.2 fl oz

35.2-38.7 fl oz

1.0-1.1


A GENERAL INFORMATION GI

SECTION

GENERAL INFORMATION

B

C

D

CONTENTS PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Description ............................................................... 3 General Precautions ................................................ 3 Precautions for Three Way Catalyst ......................... 5 Precautions for Fuel (Unleaded Regular Gasoline Recommended) ........................................................ 5 Precautions for Fuel (Unleaded Premium Gasoline Required) ................................................................. 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 How to Follow Trouble Diagnoses ............................ 8 DESCRIPTION ...................................................... 9 HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES ................................................. 9 HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION ....................................... 10 KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES ................................11 How to Read Wiring Diagrams ............................... 13 CONNECTOR SYMBOLS ................................... 13 SAMPLE/WIRING DIAGRAM — EXAMPL — ..... 14 DESCRIPTION .................................................... 16 Abbreviations ......................................................... 21 SERVICE INFORMATION FOR ELECTRICAL INCI-

DENT ......................................................................... 22 How to Check Terminal ........................................... 22 CONNECTOR AND TERMINAL PIN KIT ............ 22 HOW TO PROBE CONNECTORS ...................... 22 How to Perform Efficient Diagnosis for an Electrical Incident ................................................................... 25 WORK FLOW ...................................................... 25 INCIDENT SIMULATION TESTS ........................ 25 CIRCUIT INSPECTION ....................................... 28 Control Units and Electrical Parts ........................... 33 PRECAUTIONS .................................................. 33 SMJ INSTALLATION ........................................... 34 CONSULT-II CHECKING SYSTEM .......................... 35 Description .............................................................. 35 Function and System Application ........................... 35 Nickel Metal Hydride Battery Replacement ............ 35 Checking Equipment .............................................. 35 CONSULT-II Data Link Connector (DLC) Circuit ... 36 INSPECTION PROCEDURE .............................. 36 LIFTING POINT ......................................................... 37 Lifting Points ........................................................... 37 PANTOGRAPH JACK ......................................... 37 GARAGE JACK AND SAFETY STAND .............. 37 2-POLE LIFT ....................................................... 38 TOW TRUCK TOWING ............................................. 39 Tow Truck Towing ................................................... 39 2WD MODELS .................................................... 39 4WD MODELS .................................................... 40 Vehicle Recovery (Freeing a stuck vehicle) ............ 40 TIGHTENING TORQUE OF STANDARD BOLTS ... 41 Tightening Torque Table ......................................... 41 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ............................................................... 42 Recommended Chemical Products and Sealants... 42 IDENTIFICATION INFORMATION ............................ 43 Model Variation ....................................................... 43 Identification Number .............................................. 45 VEHICLE IDENTIFICATION NUMBER ARRANGEMENT ................................................ 45 ENGINE SERIAL NUMBER ................................ 46

GI-1

E

F

G

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TRANSFER SERIAL NUMBER ........................... 46 MANUAL TRANSMISSION NUMBER ................. 46 AUTOMATIC TRANSMISSION NUMBER ........... 47

Dimensions .............................................................47 Wheels & Tires ........................................................48 TERMINOLOGY ........................................................49 SAE J1930 Terminology List ...................................49

GI-2


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

GI

EAS00123

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.

Description

General Precautions

D

E

F

G

H

EAS00125

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.

I

J

K

SGI285

C

EAS00124

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

B

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.

M

SGI231

GI-3

L


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

GI-4


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

EAS00126

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 (Unleaded Regular Gasoline Recommended)

EAS00127

C

D

E

F

Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research octane number 91). G

CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. 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 Fuel (Unleaded Premium Gasoline Required)

H

EAS00128

Use unleaded premium gasoline with an octane rating of at least 91 AKI (Anti-Knock Index) number (Research octane number 96).

I

If unleaded premium gasoline is not available, unleaded regular gasoline with an octane rating of at least 87 AKI number (Research octane number 91) can be used, but only under the following precautions: ● have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gasoline as soon as possible. ● avoid full throttle driving and abrupt acceleration. However, for maximum vehicle performance, the use of unleaded premium gasoline is recommended.

J

K

L

CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. 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 ●

● ●

EAS00129

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

GI-5

M


PRECAUTIONS Precautions for Hoses

EAS0012A

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

EAS0012B

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.

GI-6


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

F

G

EAS0012C

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

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GI-7


HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL Description

PFP:00008 EAS0012D

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

Terms ●

EAS0012E

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 ●

EAS0012F

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

EAS0012G

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.

● ● ● ●

How to Follow Trouble Diagnoses

EAS0012H

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. 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 EL 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.

GI-8


HOW TO USE THIS MANUAL DESCRIPTION GI 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 B “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 C 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 D 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. E 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. F

HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES G

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WGI027

1.

Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups.

GI-9


HOW TO USE THIS MANUAL 2.

Questions and required results. Questions and required results are indicated in bold type in test group. The meanings are as follows: a. Battery voltage → 11 - 14V or approximately 12V b. Voltage c. Resistance

3.

4.

: Approximately 0V → Less than 1V : Continuity should exist → Approximately 0Ω

Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Refer to GI-13, "CONNECTOR SYMBOLS" and GI-11, "KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES" . 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.

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.

AGI070

GI-10


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

B

C

D

E

F

G

H

SGI144A

I

KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES Symbol

Symbol explanation

Symbol

Check after disconnecting the connector to be measured.

Symbol explanation

J

Procedure with Generic Scan Tool (GST, OBD-II scan tool)

K Check after connecting the connector to be measured.

Procedure without CONSULT-II or GST

L Insert key into ignition switch.

A/C switch is OFF.

M Remove key from ignition switch.

A/C switch is ON.

Turn ignition switch to OFF position.

REC switch is ON.

Turn ignition switch to ON position.

REC switch is OFF.

Turn ignition switch to “START” position.

DEF switch is ON.

GI-11


HOW TO USE THIS MANUAL Symbol

Symbol explanation

Symbol

Symbol explanation

Turn ignition switch from OFF to ACC position.

VENT switch is ON.

Turn ignition switch from ACC to OFF position.

Fan switch is ON. (At any position except for OFF position)

Turn ignition switch from OFF to ON position.

Fan switch is OFF.

Turn ignition switch from ON to OFF position.

Apply positive voltage from battery with fuse directly to components.

Do not start engine, or check with engine stopped.

Drive vehicle.

Start engine, or check with engine running.

Disconnect battery negative cable.

Apply parking brake.

Depress brake pedal.

Release parking brake.

Release brake pedal.

Check after engine is warmed up sufficiently.

Depress accelerator pedal.

Voltage should be measured with a voltmeter.

Release accelerator pedal.

Circuit resistance should be measured with an ohmmeter.

Pin terminal check for SMJ type ECM and TCM connectors. For details regarding the terminal arrangement, refer to PG-62, "Terminal Arrangement" .

Current should be measured with an ammeter.

Procedure with CONSULT-II

Procedure without CONSULT-II

GI-12


HOW TO USE THIS MANUAL How to Read Wiring Diagrams

EAS0012I

GI

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-4, "Description" .

B

C

D

E

F

G

SGI364

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

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SGI363

GI-13


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

For Description, refer to GI-16, "DESCRIPTION" .

SGI091A

GI-14


HOW TO USE THIS MANUAL Optional Splice GI

B

C

D

E

F

G

H

SGI942

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GI-15


HOW TO USE THIS MANUAL DESCRIPTION Number

Item

1

Power condition

2

Fusible link

3

Fusible link/fuse location

4

Fuse

5

Current rating

6

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-9, "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 "Reference Area".

7

Optional splice

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

8

Splice

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

9

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.

10

Common connector

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

11

Option abbreviation

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

12

Relay

This shows an internal representation of the relay. For details, refer to PG-7, "STANDARDIZED RELAY" .

13

Connectors

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

This shows a code for the color of the wire.

14

Wire color

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

BR = Brown OR = Orange P = Pink PU = Purple GY = Gray SB = Sky Blue CH = Dark Brown DG = Dark 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

16

Switch

17

Assembly parts

18

Cell code

19

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 “ operation.

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

Current flow arrow ” shows that current can flow in either direction depending on circuit

20

System branch

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

21

Page crossing

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

22

Shielded line

The line enclosed by broken line circle shows shield wire.

GI-16


HOW TO USE THIS MANUAL Number

Item

Description

23

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.

24

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-33, "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 PG17, "GROUND" .

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 the power supply routing. Refer to PG-9, "POWER SUPPLY ROUTING" . The open square shows current flow in, and the shaded square shows current flow out.

This shows that more information on the SMJ (Super Multiple Junction), Electrical Units, etc. exists on the at the end of the manual. Refer to "Reference Area" for details.

25

Connector number

26

Ground (GND)

27

Ground (GND)

28

Connector views

29

Common component

30

Connector color

31

Fusible link and fuse box

32

Reference area

GI

B

Switch Positions

C

D

E

F

G

H

I

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. ● Parking brake is released.

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SGI860

GI-17


HOW TO USE THIS MANUAL Detectable Lines and Non-detectable Lines In some wiring diagrams, two kinds of lines, representing wires, with different weight are used. ● 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.

AGI095

GI-18


HOW TO USE THIS MANUAL Multiple Switch GI

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

B

C

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GI-19


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

SGI092A

SMJ (Super Multiple Junction) In a wiring diagram, the SMJ connectors include a letter of the alphabet in the terminal number. SMJ connector numbers are shown in the Reference Area of the wiring diagram. SMJ terminal arrangement can be found on the electrical reference pages at the end of the manual. For terminal arrangement of these connectors, refer to the “SMJ (SUPER MULTIPLE JUNCTION)” electrical reference page at the end of the manual. Fuse block—Junction Box (J/B) Fuse block—Junction Box (J/B) connector number is shown in the Reference Area of the wiring diagram. For connector terminal and fuse arrangement, refer to the “FUSE BLOCK—Junction Box (J/B)” electrical reference page at the end of the manual.

GI-20


HOW TO USE THIS MANUAL Fuse and fusible link box For fuse arrangement in the fuse and fusible link box, refer to the “FUSE AND FUSIBLE LINK BOX” elec- GI trical reference page at the end of the manual. ● Electrical units Electrical unit connector symbols are shown in the Connector Area of the wiring diagram. However, when B there is not enough space to show the connector terminal arrangement in the Connector Area of the wiring diagram, the electrical unit connector number is shown in the Reference Area of the wiring diagram. For electrical unit connector terminal arrangement, refer to the “ELECTRICAL UNITS” electrical reference page at the end of the manual. Most of the electrical unit connectors on this page are shown from the har- C ness side forth connector. ● Joint Connector Joint Connector symbols are shown in the connector area of the wiring diagram. For connector internal D wiring layout and joint connector terminal arrangement, refer to the “JOINT CONNECTOR” electrical reference page at the end of the manual. E Abbreviations EAS0012J ●

The following ABBREVIATIONS are used: ABBREVIATION

DESCRIPTION

A/C

Air Conditioner

A/T

Automatic Transaxle/Transmission

ATF

Automatic Transmission Fluid

D1

Drive range 1st gear

D2

Drive range 2nd gear

D3

Drive range 3rd gear

D4

Drive range 4th gear

FR, RR

Front, Rear

LH, RH

Left-Hand, Right-Hand

G

H

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M/T

Manual Transaxle/Transmission

OD

Overdrive

P/S

Power Steering

SAE

Society of Automotive Engineers, Inc.

SDS

Service Data and Specifications

SST

Special Service Tools

2WD

2-Wheel Drive

22

2nd range 2nd gear

21

2nd range 1st gear

12

1st range 2nd gear

11

1st range 1st gear

F

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GI-21


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

PFP:00000 EAS0012K

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

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

GI-22


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.

GI

B

C SEL266V

D

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

E

F

G SEL267V

How to Check Enlarged Contact Spring of Terminal

H

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.

I

J

K

L SEL270V

3.

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.

M

SEL271V

GI-23


SERVICE INFORMATION FOR ELECTRICAL INCIDENT 4.

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

SEL272V

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

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. 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.

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

GI-24


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

EAS0012L

GI

WORK FLOW

B

C

D

E

F

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

G

Power Supply Routing

System Operation Descriptions

Applicable Service Manual Sections

Check for any Service Bulletins

H

I

J

K

L

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

GI-25

M


SERVICE INFORMATION FOR ELECTRICAL INCIDENT Freezing ● Water intrusion ● Electrical load ● Cold or hot start up 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

GI-26


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 GI pinching.

Heat Sensitive B

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 60°C (140°F). If incident occurs while heating the unit, either replace or properly insulate the component.

C

D

SGI842

E

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.

F

G

H

SGI843

I

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.

J

K

L

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.

GI-27

M


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.

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.

GI-28


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. ●

GI

B

C

D

Testing for “Shorts” in the Circuit E

To simplify the discussion of shorts in the system, please refer to the following schematic.

F

G

H 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). ●

GI-29

I

J

K

L

M


SERVICE INFORMATION FOR ELECTRICAL INCIDENT

no voltage; short is further down the circuit than the relay. 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.

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.

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

GI-30


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. GI ● Operate the circuit. ● The DMM will indicate how many volts are being used to “push” current through that part of the circuit. B Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb. ●

C

D

E

F

G

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.

H

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M

SAIA0258E

GI-31


SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Unit Circuit Test System Description:When the switch is ON, the control unit lights up the lamp.

MGI034A

INPUT-OUTPUT VOLTAGE CHART Pin No. 1

Item Switch

2

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

Approx. 0

Switch ON

Battery voltage

Approx. 0 (Inoperative lamp)

Switch OFF

Approx. 0

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

1

Lamp

2

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

Battery voltage

Switch ON

Approx. 0

Higher than 0 Approx. 4 (Example)

Switch OFF

Approx. 5

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.

GI-32


SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Units and Electrical Parts

EAS0012M

GI

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.

B

C

D SAIA0251E

E

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.

F

G

H 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.

I

J

K

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.

M

SAIA0254E

GI-33

L


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.

SAIA0255E

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

SMJ INSTALLATION To install SMJ, tighten bolts until orange “fulltight” mark appears and then retighten to specified torque as required. SMJ

:3 - 5 N·m (0.3 - 0.5 kg-m, 26 - 43 in-lb)

CAUTION: Do not overtighten bolts, otherwise, they may be damaged.

CEL969

GI-34


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

PFP:00000

GI EAS0012N

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

EAS0012O

B

C

Function

Engine

A/T

Air bag

ABS

ABS (Including VDC)

Air Pressure Monitor

Work support

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

x

x

x

DTC work support

Select the operating condition to confirm Diagnosis Trouble Codes.

x

Self-diagnostic results

Self-diagnostic results can be read and erased quickly.

x

x

x

x

x

x

Trouble diagnostic record

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

x

ECU discriminated No.

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

x

Data monitor

Input/Output data in the ECU (ECM) can be read.

x

x

x

x

x

I

Data monitor (Spec.)

The specified values will be displayed when an OK/NG judgment is difficult for the DATA MONITOR items by Bar Chart and Line Graph.

x

J

Active test

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

x

x

x

K

SRT & DTC confirmation

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

x

x*

L

ECU (ECM) part number

ECU (ECM) part number can be read.

x

x

x

x

x

Diagnostic test mode

D

E

F

G

x: Applicable *: For VG33E and VG33ER engine

Nickel Metal Hydride Battery Replacement

EAS0012P

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

EAS0012Q

When ordering the below equipment, contact your NISSAN distributor.

GI-35

H

M


CONSULT-II CHECKING SYSTEM Tool name

Description

NISSAN CONSULT-II 1 CONSULT-II unit (Tester internal soft: Resident Version 3.3.0) and accessories 2 Program card AED03B 3 CAN converter

For details, refer to Consult-II Operation Manual. LAIA0038E

CONSULT-II Data Link Connector (DLC) Circuit

EAS0012R

LAIA0028E

INSPECTION PROCEDURE If the CONSULT-II cannot diagnose the system properly, check the following items. 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)

CONSULT-II DLC cable

CONSULT-II program card (Check the appropriate CONSULT-II program card for the system. Refer to "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.)

NOTE: The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be 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.

GI-36


LIFTING POINT LIFTING POINT Lifting Points

PFP:00000

GI EAS0012S

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.

B

C

PANTOGRAPH JACK

D

E

F

G

H

LAIA0040E

I

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

J

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L

M

AGI113

GI-37


LIFTING POINT 2-POLE LIFT WARNING: 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. When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, or fuel lines.

WGI025

GI-38


TOW TRUCK TOWING TOW TRUCK TOWING Tow Truck Towing

PFP:00000

GI EAS0012T

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 power train 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.

B

C

D

E

F

G

H AGI077

I

2WD MODELS 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 shift lever to the neutral position. On automatic transmission models, to move the 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. ● When towing manual transmission models with the rear wheels on the ground (if you do not use a towing dollies): Always release the parking brake and move the transmission shift lever to the neutral position. Observe the following restricted towing speeds and distances. Speed Distance

J

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M

: Below 95 km/h (60 MPH) : Less than 800 km (500 miles)

SGI976

GI-39


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

WGI022

4WD MODELS 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 or rear wheels on the ground (If you do not use towing dollies): Set the free-running hubs to the free position and move the transfer case shift lever into the “2H” position. ● When towing with the front on the ground: Turn the ignition key to the 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. ● When towing manual transmission models with the rear wheels on the ground: Always release the parking brake and move the transmission shift lever to the neutral position. Observe the following restricted towing speeds and distances. Speed Distance

: Below 95 km/h (60 MPH) : Less than 800 km (500 miles) SGI973

Vehicle Recovery (Freeing a stuck vehicle) ● ● ● ●

EAS0012U

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.

GI-40


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

Bolt size

M6 M8

4T

M10

M12

7T

6.0 8.0

10.0

12.0

GI EAS0012V

Tightening torque (Without lubricant) Pitch mm

Hexagon head bolt N·m

kg-m

B

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

13

1.3

9

15

1.5

11

1.0

13

1.3

9

16

1.6

12

1.5

25

2.5

18

29

3.0

22

1.25

25

2.6

19

30

3.1

22

1.75

42

4.3

31

51

5.2

38

1.25

46

4.7

34

56

5.7

41

M14

14.0

1.5

74

7.5

54

88

9.0

65

M6

6.0

1.0

8.4

0.86

6.2

74.6

10

1.0

7

87

M8

8.0

1.25

21

2.1

15

25

2.5

18

1.0

22

2.2

16

26

2.7

20

1.5

41

4.2

30

48

4.9

35

M10

M12

9T

Bolt diameter * mm

PFP:00000

10.0

12.0

1.25

43

4.4

32

51

5.2

38

1.75

71

7.2

52

84

8.6

62

1.25

77

7.9

57

92

9.4

68

M14

14.0

1.5

127

13.0

94

147

15.0

108

M6

6.0

1.0

12

1.2

9

15

1.5

11

M8

8.0

1.25

29

3.0

22

35

3.6

26

1.0

31

3.2

23

37

3.8

27

1.5

59

6.0

43

70

7.1

51

M10

M12 M14

10.0

12.0 14.0

1.25

62

6.3

46

74

7.5

54

1.75

98

10.0

72

118

12.0

87

1.25

108

11.0

80

137

14.0

101

1.5

177

18.0

130

206

21.0

152

C

D

E

F

G

H

I

J

K

L

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

M

MGI044A

GI-41


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

PFP:00000 EAS00158

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

1

2

3

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

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)

6

Aftermarket Crossreference Part Nos.

Used to permanently remount rear view mirrors to windows.

Gasket Maker

5

NISSAN Canada Part No. (Canada)

Rear View Mirror Adhesive

4

NISSAN North America Part No. (USA)

High Temperature, High Strength Thread Locking Sealant (Red)

Medium Strength Thread Locking Sealant (Blue)

Threadlocker

Threadlocker (service tool removable)

999MP-AM004P

999MP-AM005P

GI-42

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


IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION Model Variation

PFP:00010

GI EAS0012X

B

C

D

E

F

G

H

I WGI035

J

K

L

M

GI-43


IDENTIFICATION INFORMATION Drive Type

4x2

Body

King Cab

Engine

KA24DE

VG33E

Transmission

Canada

XE

BBGGLEF-EUN

BBGGLEF-ENN

Auto

XE

BBGGLEB-EUN

BBGGLEB-ENN

Manual

XE

BLPGLEF-EUN

BLPGLEF-ENN

SE

XE

BLPGLEA-EUN

BLPGLEA-ENN

SE

Manual

XE

CLPGLEF-EUN

SE

XE

CLPGLEA-EUN

SE

XE

CLP5LEF-EUN

CLP5LEF-ENN

SE

XE

CLP5LEA-EUN

CLP5LEA-ENN

SE

Manual

SC

Auto

SC

Crew Cab Short Bed

Manual

SC

Auto

SC

CLPGLMA-RUN

Crew Cab Long Bed

Manual

SC

Auto

SC

CLP5LMA-RUN

CLP5LMA-RNN

Manual

XE

BLPULEF-EUN

BLPULEF-ENN

Auto

Crew Cab Long Bed

Manual

Auto

King Cab

4X4

Model U.S.A.

Manual

Auto

Crew Cab Short Bed

Grade

King Cab

VG33ER

VG33E

SE

XE

BLPULEA-EUN

BLPULEA-ENN

SE

XE

CLPULEF-EUN

SE

XE

CLPULEA-EUN

SE

Manual

XE

CLP9LEF-EUN

CLP9LEF-ENN

SE

Auto

XE

CLP9LEA-EUN

CLP9LEA-ENN

SE

CLP9LFA-ENN

Manual

SC

BLPULMF-RUN

Auto

SC

BLPULMA-RUN

Crew Cab Short Bed

Manual

SC

Auto

SC

CLPULMA-RUN

Crew Cab Long Bed

Manual

SC

Auto

SC

CLP9LMA-RUN

CLP9LMA-RNN

Auto

Crew Cab Short Bed

Manual

Auto

Crew Cab Long Bed

King Cab

VG33ER

GI-44


IDENTIFICATION INFORMATION Identification Number

EAS0012Y

GI

B

C

D

E

F WAIA0050E

G

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

H

I

J

K

L

M

WAIA0051E

GI-45


IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER

AGI106

WGI029

TRANSFER SERIAL NUMBER

AGI108

MANUAL TRANSMISSION NUMBER

AGI109

GI-46


IDENTIFICATION INFORMATION AUTOMATIC TRANSMISSION NUMBER GI

B

C AGI110

D

E

F

G AGI111

Dimensions

EAS0012Z

Unit: mm (in) Drive Type Body Overall Length*1 Overall Width (excludes mirrors) Overall Height

Front Tread Rear Tread

Wheelbase Minimum Running Ground Clearance (at Front Suspension)

2WD

H

4WD

King Cab

Crew Cab

Crew Cab Long Bed

King Cab

Crew Cab

Crew Cab Long Bed

5153 (202.9)

5077 (199.9)

5532 (217.8)

5153 (202.9)

5077 (199.9)

5532(217.8)

1725 (67.7)*2 1808 (71.2)*3, *4

1808 (71.2)

1808 (71.2)

1808 (71.2)

1808 (71.2)

1808 (71.2)

1605 (63.2)*2 1694 (66.7)*3

1694 (66.7)*3 1775 (69.9)*4

1694 (66.7)*3 1775 (69.9)*4

1694 (66.7)

1704 (67.1)*3 1823 (71.8)*4 1836 (72.3)*5

1704 (67.1)*3 1823 (71.8)*4 1836 (72.3)*5

K

1395 (54.9)*2 1525 (60)*3

1525 (60)

1525 (60)

1525 (60)

1525 (60)

1525 (60)

L

1390 (54.7)*2 1507 (59.3)*3, *4

1507 (59.3)

1507 (59.3)

1507 (59.3)

1507 (59.3)

1507 (59.3)

2950 (116.1)

2950 (116.1)

3329.9 (131.1)

2950 (116.1)

2950 (116.1)

3329.9 (131.1)

170 (6.7)*2 246 (9.7)*3 244 (9.6)*4

246 (9.7)*3 244 (9.6)*4

246 (9.7)*3 244 (9.6)*4

244 (9.6)*3 249 (9.8)*4

244 (9.6)*3 249 (9.8)*4, *5

244 (9.6)*3 249 (9.8)*4, *5

I

J

M

*1: The step bumper adds 175 mm (6.9 in) to the overall length. *2: XE with KA24DE engine. *3: XE with VG33E engine. *4: SC models. *5: SE models

GI-47


IDENTIFICATION INFORMATION Wheels & Tires Drive Type 4x2

4x4

EAS00130

Grade

Road wheel

Spare tire size

P225/70R15

T135/90D16

15x7JJ Steel, 15x7JJ Alloy

P265/70R15*

P265/70R15*

SE

16x7JJ Alloy

P255/65R16

P255/65R16

SC

17x7JJ Alloy

P265/55R17

P265/55R17

XE

15x7JJ Steel, 15x7JJ Alloy

P265/70R15

P265/70R15

SE

16x7JJ Alloy

P265/70R16

P265/70R16

SC

16x7JJ Alloy, 17x7JJ Alloy

P265/70R16, P265/65R17

P265/70R16, P265/65R17

XE

15x6JJ Steel, 15x7JJ Alloy

Tire

*: Not available with KA24DE engine.

GI-48


TERMINOLOGY TERMINOLOGY SAE J1930 Terminology List

PFP:00011

GI EAS00131

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

B

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

CL

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

***

C

D

E

F

G

H

I

J

K

L

M

Electronic ignition system

EI system

Ignition timing control

Engine control

EC

***

Engine control module

ECM

ECCS control unit

Engine coolant temperature

ECT

Engine temperature

Engine coolant temperature sensor

ECTS

Engine temperature sensor

Engine modification

EM

***

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

EGR valve

GI-49


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

FT

***

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

IC

***

Ignition control module

ICM

***

Indirect fuel injection system

IFI system

***

Intake air

IA

Air

Exhaust gas recirculation temperature sensor EGR temperature sensor

Intake air temperature sensor

IAT sensor

Air temperature sensor

Knock

***

Detonation

Knock sensor

KS

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

GI-50


TERMINOLOGY NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Nonvolatile random access memory

NVRAM

***

On board diagnostic system

OBD system

Self-diagnosis

Open loop

OL

Open loop

Oxidation catalyst

OC

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

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

ST

***

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

SC

***

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

TB

Throttle chamber SPI body

Throttle body fuel injection system

TBI system

Fuel injection control

Throttle position

TP

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

GI-51

GI

B

C

D

E

F

G

H

I

J

K

L

M


TERMINOLOGY NEW ACRONYM / ABBREVIATION

NEW TERM

OLD TERM

Transmission control module

TCM

A/T control unit

Turbocharger

TC

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

GI-52


B ENGINE A

SECTION

ENGINE MECHANICAL

EM

C

D

CONTENTS KA24DE PRECAUTIONS .......................................................... 4 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 4 Parts Requiring Angular Tightening ......................... 4 Precautions for Liquid Gasket .................................. 5 REMOVAL OF LIQUID GASKET SEALING .......... 5 LIQUID GASKET APPLICATION PROCEDURE..... 5 PREPARATION ........................................................... 6 Special Service Tools ............................................... 6 Commercial Service Tools ........................................ 8 NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING ...............................................11 Noise, Vibration and Harshness (NVH) ...................11 NVH TROUBLESHOOTING CHART — ENGINE NOISE ................................................................. 12 OUTER COMPONENT PARTS ................................ 13 Removal and Installation ........................................ 13 OIL PAN .................................................................... 16 Components ........................................................... 16 Removal ................................................................. 16 Installation .............................................................. 17 TIMING CHAIN ......................................................... 19 Components ........................................................... 19 LIQUID GASKET APPLICATION PLACES ......... 20 Removal ................................................................. 20 UPPER TIMING CHAIN ...................................... 21 IDLER SPROCKET ............................................. 21 LOWER TIMING CHAIN ..................................... 22 Inspection ............................................................... 24 Installation .............................................................. 24 LOWER TIMING CHAIN ..................................... 24 IDLER SPROCKET ............................................. 26 UPPER TIMING CHAIN ...................................... 26 OIL SEAL .................................................................. 28 Replacement .......................................................... 28 VALVE OIL SEAL ................................................ 28 FRONT OIL SEAL ............................................... 28 REAR OIL SEAL ................................................. 30

CYLINDER HEAD ..................................................... 32 On-Vehicle Service ................................................. 32 CHECKING COMPRESSION PRESSURE ......... 32 Components ........................................................... 33 Removal ................................................................. 33 Disassembly ........................................................... 34 Inspection ............................................................... 34 CYLINDER HEAD DISTORTION ........................ 34 CAMSHAFT VISUAL CHECK ............................. 35 CAMSHAFT RUNOUT ........................................ 35 CAMSHAFT CAM HEIGHT ................................. 35 CAMSHAFT JOURNAL CLEARANCE ................ 36 CAMSHAFT END PLAY ...................................... 36 CAMSHAFT SPROCKET RUNOUT .................... 36 VALVE GUIDE CLEARANCE .............................. 37 VALVE GUIDE REPLACEMENT ......................... 37 VALVE SEATS ..................................................... 39 REPLACING VALVE SEAT ................................. 39 VALVE DIMENSIONS .......................................... 40 VALVE SPRING ................................................... 40 VALVE LIFTER AND ADJUSTING SHIM ............ 41 Assembly ................................................................ 42 Installation .............................................................. 42 Valve Clearance ..................................................... 43 CHECKING ......................................................... 43 ADJUSTING ........................................................ 44 ENGINE ASSEMBLY ................................................ 46 Removal and Installation ........................................ 46 REMOVAL ........................................................... 47 INSTALLATION ................................................... 47 CYLINDER BLOCK .................................................. 48 Components ........................................................... 48 Removal and Installation ........................................ 49 Disassembly ........................................................... 49 PISTON AND CRANKSHAFT ............................. 49 Inspection ............................................................... 50 PISTON AND PISTON PIN CLEARANCE .......... 50 PISTON RING SIDE CLEARANCE ..................... 51 PISTON RING END GAP .................................... 51 CONNECTING ROD BEND AND TORSION ...... 51

EM-1

E

F

G

H

I

J

K

L

M


CYLINDER BLOCK DISTORTION AND WEAR... 52 PISTON-TO-CYLINDER BORE CLEARANCE ... 52 CRANKSHAFT .................................................... 53 BEARING CLEARANCE ..................................... 54 CONNECTING ROD BUSHING CLEARANCE (SMALL END) ...................................................... 57 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) .................................... 58 FLYWHEEL/DRIVE PLATE RUNOUT ................. 58 Assembly ................................................................ 58 PISTON ............................................................... 58 CRANKSHAFT .................................................... 60 REPLACING PILOT BUSHING ........................... 61 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 63 General Specifications ............................................ 63 COMPRESSION PRESSURE ............................. 63 Cylinder Head ......................................................... 63 Valve ....................................................................... 63 VALVE .................................................................. 63 VALVE SPRING ................................................... 64 VALVE GUIDE ..................................................... 64 VALVE LIFTER .................................................... 64 VALVE CLEARANCE ADJUSTMENT ................. 65 AVAILABLE SHIMS ............................................. 65 VALVE SEAT ....................................................... 66 Cylinder Block ......................................................... 67 Camshaft and Camshaft Bearing ........................... 68 Piston, Piston Ring and Piston pin ......................... 69 PISTON ............................................................... 69 PISTON PIN ........................................................ 69 PISTON RING ..................................................... 69 Connecting Rod ...................................................... 70 Crankshaft .............................................................. 70 Bearing Clearance .................................................. 71 Available Main Bearing ........................................... 71 STANDARD ......................................................... 71 UNDERSIZE (SERVICE) ..................................... 71 Available Connecting Rod Bearing ......................... 71 STANDARD ......................................................... 71 UNDERSIZE (SERVICE) ..................................... 71 Miscellaneous Components .................................... 71

VG33E and VG33ER PRECAUTIONS ......................................................... 72 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ................................................................. 72 Parts Requiring Angular Tightening ........................ 72 Precautions for Liquid Gasket ................................ 73 REMOVAL OF LIQUID GASKET SEALING ........ 73 LIQUID GASKET APPLICATION PROCEDURE... 73 PREPARATION ......................................................... 74 Special Service Tools ............................................. 74 Commercial Service Tools ...................................... 76 NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING .............................................. 78 Noise, Vibration and Harshness (NVH) .................. 78 NVH TROUBLESHOOTING CHART — ENGINE

NOISE ..................................................................79 OUTER COMPONENT PARTS .................................80 Removal and Installation .........................................80 OIL PAN .....................................................................88 Removal ..................................................................88 Installation ...............................................................89 TIMING BELT ............................................................91 Components ............................................................91 Removal ..................................................................91 Inspection ................................................................93 BELT TENSIONER AND TENSIONER SPRING...94 Installation ...............................................................94 Tension Adjustment .................................................95 AFTER BELT REPLACEMENT ...........................95 AFTER ENGINE OVERHAUL OR ENGINE REASSEMBLY (WITH ROCKER COVERS REMOVED) ..........................................................96 OIL SEAL ..................................................................99 Replacement ...........................................................99 VALVE OIL SEAL .................................................99 CAMSHAFT OIL SEAL ........................................99 FRONT OIL SEAL .............................................. 100 REAR OIL SEAL ................................................ 101 CYLINDER HEAD ................................................... 102 Measurement of Compression .............................. 102 Components .......................................................... 104 Removal ................................................................ 105 Disassembly .......................................................... 108 Inspection .............................................................. 110 CYLINDER HEAD DISTORTION ....................... 110 CAMSHAFT VISUAL CHECK ............................ 110 CAMSHAFT RUNOUT ....................................... 110 CAMSHAFT CAM HEIGHT ................................ 110 CAMSHAFT JOURNAL CLEARANCE .............. 111 CAMSHAFT END PLAY ..................................... 111 CAMSHAFT SPROCKET RUNOUT .................. 111 VALVE GUIDE CLEARANCE ............................ 112 VALVE GUIDE REPLACEMENT ....................... 113 VALVE SEATS ................................................... 114 REPLACING VALVE SEAT FOR SERVICE PARTS ............................................................... 114 VALVE DIMENSIONS ........................................ 115 VALVE SPRING ................................................. 115 ROCKER SHAFT AND ROCKER ARM ............. 116 HYDRAULIC VALVE LIFTER ............................. 116 Assembly .............................................................. 117 Installation ............................................................. 118 SUPERCHARGER .................................................. 124 Components .......................................................... 124 Removal ................................................................ 125 Inspection .............................................................. 126 SUPERCHARGER FLANGE ............................. 126 ROTOR SYSTEM .............................................. 126 SUPERCHARGER BYPASS VALVE ACTUATOR ................................................................... 126 Installation ............................................................. 127

EM-2


ENGINE ASSEMBLY .............................................. 128 Removal and Installation ...................................... 128 REMOVAL ......................................................... 129 INSTALLATION ................................................. 130 CYLINDER BLOCK ................................................ 131 Components ......................................................... 131 Removal and Installation ...................................... 132 Disassembly ......................................................... 132 PISTON AND CRANKSHAFT ........................... 132 Inspection ............................................................. 133 PISTON AND PISTON PIN CLEARANCE ........ 133 PISTON RING SIDE CLEARANCE .................. 133 PISTON RING END GAP .................................. 134 CONNECTING ROD BEND AND TORSION .... 134 CYLINDER BLOCK DISTORTION AND WEAR. 134 PISTON-TO-BORE CLEARANCE .................... 135 CRANKSHAFT .................................................. 136 BEARING CLEARANCE ................................... 137 CONNECTING ROD BUSHING CLEARANCE (SMALL END) ................................................... 140 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) .................................. 140 FLYWHEEL/DRIVE PLATE RUNOUT ............... 140 Assembly .............................................................. 141 PISTON ............................................................. 141 CRANKSHAFT .................................................. 141 REPLACING PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T) ........................................... 143

SERVICE DATA AND SPECIFICATIONS (SDS) .... 144 General Specifications .......................................... 144 Cylinder Head ....................................................... 145 Valve ..................................................................... 145 VALVE ............................................................... 145 VALVE SPRING ................................................. 145 HYDRAULIC VALVE LIFTER ............................ 146 VALVE GUIDE ................................................... 146 ROCKER SHAFT AND ROCKER ARM ............ 146 Valve Seat ............................................................ 147 INTAKE VALVE SEAT ........................................ 147 EXHAUST VALVE SEAT ................................... 148 Camshaft and Camshaft Bearing ......................... 148 Cylinder Block ....................................................... 149 Piston, Piston Ring and Piston Pin ....................... 150 AVAILABLE PISTON ......................................... 150 PISTON RING ................................................... 150 PISTON PIN ...................................................... 151 Connecting Rod .................................................... 151 Crankshaft ............................................................ 152 Available Main Bearing ......................................... 153 NO. 1 MAIN BEARING ...................................... 153 NO. 2 AND 3 MAIN BEARING .......................... 153 NO. 4 MAIN BEARING ...................................... 153 UNDER SIZE ..................................................... 153 Available Connecting Rod Bearing ....................... 154 CONNECTING ROD BEARING UNDERSIZE . 154 Miscellaneous Components ................................. 154 BEARING CLEARANCE ................................... 154

A

EM

C

D

E

F

G

H

I

J

K

L

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EM-3


PRECAUTIONS [KA24DE] PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

EBS00GS0

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 may include seat belt switch inputs and dual stage front air bag modules. If equipped with 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. The vehicle may be equipped with a passenger air bag deactivation switch. Because no rear seat exists where a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is enabled and could inflate for certain types of collision. When the switch is turned to the OFF position, the passenger air bag is disabled and will not inflate. A passenger air bag OFF indicator on the instrument panel lights up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected by the passenger air bag deactivation switch. 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. ● The vehicle may be equipped with a passenger air bag deactivation switch which can be operated by the customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and will not inflate. When the passenger air bag is switched ON, the passenger air bag is enabled and could inflate for certain types of collision. After SRS maintenance or repair, make sure the passenger air bag deactivation switch is in the same position (ON or OFF) as when the vehicle arrived for service.

Parts Requiring Angular Tightening ●

– – ● ● ●

EBS00GS1

Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Connecting rod cap nuts 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.

EM-4


PRECAUTIONS [KA24DE]

Precautions for Liquid Gasket

EBS00GS2

A

REMOVAL OF LIQUID GASKET SEALING After removing the mounting bolts and nuts, disconnect the component using a seal cutter. CAUTION: Be careful not to damage the mating surfaces. ● Use a plastic hammer to lightly tap (1) the areas where the liquid gasket is applied. To advance the cutter, use a plastic hammer (2) to slide the cutter along the joint. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces. ●

EM

C

D PBIC0275E

LIQUID GASKET APPLICATION PROCEDURE 1.

E

Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. ● Remove the sealant completely from the groove of the gasket application surface, mounting bolts, and bolt holes.

F

G

H PBIC0003E

2. 3.

Thoroughly clean the gasket application surface and the mating surface and remove adhering moisture, grease and foreign materials. Attach the sealant tube to the tube presser.

I

J

K

L EMA0622D

4.

Apply the sealant without breaks to the specified location with the specified dimensions. ● If there is a groove for the sealant application, apply the sealant to the groove. ● As for the bolt holes, normally apply the sealant inside the holes. If specified, it should be applied outside the holes. Make sure to read the text of this manual. ● Within five minutes of the sealant application install the mating component. ● If the sealant protrudes, wipe it off immediately. SEM159F ● Do not retighten after the installation. ● After 30 minutes or more have passed from the installation, fill the engine with the specified oil and coolant. Refer to MA-20, "Changing Engine Oil" and MA-17, "REFILLING ENGINE COOLANT" .

EM-5

M


PREPARATION [KA24DE]

PREPARATION Special Service Tools

PFP:00002 EBS00GS3

The actual shapes of Kent-Moore tools may differ from those of the special service tools illustrated here. Tool number (Kent-Moore No.) Description Tool name ST0501S000 ( — ) Engine stand assembly 1 ST05011000 ( — ) Engine stand 2 ST05012000 ( — ) Base

Disassembling and assembling

NT042

KV10105001 ( — ) Engine attachment

NT031

KV101092S0 (J26336-B) Valve spring compressor 1 KV10109210 ( — ) Compressor 2 KV100109220 ( — ) Adapter

Disassembling and assembling valve components

WEM044

KV10112100 (BT8653-A) Angle wrench

Tightening bearing cap, cylinder head bolts, etc.

NT014

KV10116300 (J-38955) Valve oil seal drift

Installing valve oil seal a: 25 (0.98) dia. b: 14.4 (0.567) dia. c: 11.8 (0.465) dia. d: 10 (0.39) dia. e: 11 (0.43) f: 9 (0.35) WEM151

EM-6


PREPARATION [KA24DE] Tool number (Kent-Moore No.) Tool name KV10110300 ( — ) Piston pin press stand assembly 1 KV10110310 ( — ) Cap 2 KV10110330 ( — ) Spacer 3 ST13030020 ( — ) Press stand 4 ST13030030 ( — ) Spring 5 KV10110340 ( — ) Drift 6 KV10110320 ( — ) Center shaft

Description Disassembling and assembling piston with connecting rod

A

EM

C

D

E WEM150

F

G

EM03470000 (J-8037) Piston ring compressor

Installing piston assembly into cylinder bore

H

I NT044

(J-36467) Valve oil seal remover

Removing valve oil seal

J

K NT034

ST16610001 (J-23907) Pilot bushing puller

Removing crankshaft pilot bushing

L

M NT045

KV10111100 (J-37228) Seal cutter

Removing oil pan

NT046

WS39930000 ( — Tube presser

Pressing the tube of liquid gasket )

NT052

EM-7


PREPARATION [KA24DE] Tool number (Kent-Moore No.) Tool name KV101151S0 (J-38972) Lifter stopper set 1 KV10115110 (J-38972-1) Camshaft pliers 2 KV10115120 (J-38972-2) Lifter stopper

Description Changing valve lifter shims

S-NT041

KV10117100 (J-36471-A) Front heated oxygen sensor wrench

Loosening or tightening heated oxygen sensor For 22 mm (0.87 in) hexagon nut

NT379

KV10114700 (J-38139) Main bearing cap remover

Removing crankshaft main bearing cap For No. 3 and No. 5 bearings

ZZA0023D

— (J-45499) Ring gear stopper

Preventing crankshaft rotation

LBIA0362E

Commercial Service Tools

EBS00GS4

Tool name (Kent-Moore No.)

Description

Spark plug wrench

Removing and installing spark plug

NT047

Pulley holder

Holding camshaft pulley while tightening or loosening camshaft bolt

NT035

EM-8


PREPARATION [KA24DE] Tool name (Kent-Moore No.)

Description

Valve seat cutter set

Finishing valve seat dimensions

A

EM

C NT048

Piston ring expander

Removing and installing piston ring

D

E NT030

Valve guide drift

Removing and installing valve guide Intake & Exhaust: a = 10.5 mm (0.413 in) dia. b = 6.6 mm (0.260 in) dia.

F

G NT015

Valve guide reamer

NT016

Front oil seal drift

Reaming valve guide 1 or hole for oversize valve guide 2 Intake: d1 = 7.0 mm (0.276 in) dia. d2 = 11.2 mm (0.441 in) dia. Exhaust: d1 = 8.0 mm (0.315 in) dia. d2 = 12.2 mm (0.480 in) dia. Installing front oil seal a: 52 mm (2.05 in) dia. b: 44 mm (1.73 in) dia.

H

I

J

K

L NT049

Rear oil seal drift

Installing rear oil seal a: 46 mm (1.81 in) b: 110 mm (4.33 in) c: 84 mm (3.31 in) d: 96 mm (3.78 in)

WEM152

Thread repair tool for oxygen sensor a: (J-43897-18) b: (J-43897-12)

a: 18 mm (0.71 in) b: 12 mm (0.47 in)

AEM488

EM-9

M


PREPARATION [KA24DE] Tool name (Kent-Moore No.)

Description

Anti-seize thread compound

For preventing corrosion, seizing, and galling on high temperature applications.

AEM489

Crankshaft pulley puller

Removing crankshaft pulley

PBIC0887E

EM-10


NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING [KA24DE]

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING Noise, Vibration and Harshness (NVH)

PFP:00003

A EBS00GS5

EM

C

D

E

F

G

H

I

J

K

L

M

AEM466

EM-11


NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING [KA24DE] NVH TROUBLESHOOTING CHART — ENGINE NOISE Use the chart below to help you find the cause of the symptom. 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of the engine. 4. Check the 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 Timing chain cover

Front of engine

Reference page

After warmup

When starting

When idling

Whe n revving

While driving

Ticking or clicking

C

A

A

B

Tappet noise

Valve clearance

EM-37

Rattle

C

A

A

B

C

Camshaft bearing noise

Camshaft journal clearance Camshaft runout

EM-36

Piston pin noise

Piston and piston pin clearance Connecting rod bushing clearance

EM-50, or EM-57

A

Piston slap noise

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

EM-51, EM-51 , EM-51 , or EM-52

Connecting rod bearing clearance (Big end) Connecting rod bushing clearance (Small end)

EM-56, or EM-57

Slap or knock Crankshaft pulley Cylinder block (upper side of engine) Oil pan

Source of noise

Before warmup

Slap or rap

A

A

B

B

B

B

Check item

Knock

A

B

C

B

B

B

Connecting rodbearing noise

Knock

A

B

A

B

C

Main bearing noise

Crankshaft runout Main bearing oil clearance

EM-53, or EM-54

Timing chain cracks and wear

EM-24

Tapping or ticking

A

A

B

B

B

Timing chain and chain tensioner noise

Squeaking or fizzing

A

B

B

C

Drive belts (Sticking or slipping)

Drive belt deflection

Creaking

A

B

A

B

A

B

Drive belts (Slipping)

Idler pulley bearing operation

Squall creak

A

B

B

A

B

Water pump noise

Water pump operation

A: Closely related

B: Related

C: Sometimes related

—: Not related:

EM-12

MA-16, "DRIVE BELT DEFLECTION AND TENSION" CO-11, "Inspection"


OUTER COMPONENT PARTS [KA24DE]

OUTER COMPONENT PARTS Removal and Installation

PFP:00100

A EBS00GS6

Engine Outer Components EM

C

D

E

F

G

H

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M

WBIA0232E

EM-13


OUTER COMPONENT PARTS [KA24DE] 1.

Throttle body

2.

EGR temperature sensor

4.

EGR tube

5.

Oil dipstick

6.

Exhaust manifold

7.

Heated oxygen sensor 1

8.

Exhaust manifold cover

9.

TWC (manifold)

10. TWC (manifold) gaskets

11. Exhaust manifold gaskets

3.

EGR valve

12. Crankshaft pulley

13. Generator bracket

14. Generator

15. Water pump

16. Adjusting bar

17. Water pump pulley

18. Oil pressure switch

19. Oil filter

20. Oil filter bracket

21. Knock sensor

22. Water inlet

23. Thermostat

24. Intake manifold bracket

Ignition System Outer Components

WBIA0180E

1.

Spark plug

2.

Ignition wires

3.

Camshaft position sensor built into distributor

4.

EGR tube

5.

Exhaust manifold

6.

Heated oxygen sensor 1

7.

Exhaust manifold cover

8.

TWC (manifold)

9.

TWC (manifold) gaskets

EM-14


OUTER COMPONENT PARTS [KA24DE] A

EM

C

D

E

F

G

H

I

WBIA0099E

J

K

L

M

EM-15


OIL PAN [KA24DE]

OIL PAN Components

PFP:11110 EBS00GS7

WBIA0174E

Removal 1. 2. 3. 4.

EBS00GS8

Remove the engine under cover. Drain the engine oil. Refer to MA-20, "Changing Engine Oil" . Remove the front suspension member. Refer to FSU-10, "Front Suspension Parts" . Remove the oil pan bolts in the numerical order as shown.

AEM497

5. a.

b.

Remove the oil pan using Tool as shown. Insert Tool between the cylinder block and oil pan, and separate the oil pan from the engine block by tapping (1) with a plastic hammer as shown. â—? Be careful not to damage the aluminum mating surface. â—? Do not insert a screwdriver, which may damage the oil pan flange. Slide the Tool by tapping on the side (2) of the Tool with a plastic hammer as shown. PBIC0002E

6.

Pull the oil pan out from the front side.

EM-16


OIL PAN [KA24DE]

Installation 1.

EBS00GS9

A

Use a scraper to remove the old liquid gasket from the mating surface of the oil pan. ● Remove all traces of the liquid gasket from the mating surface of the cylinder block.

EM

C

D AEM299

2.

Apply a continuous bead of liquid gasket to the mating surface of the oil pan. ● Use Genuine Anaerobic Liquid Gasket or equivalent. Refer to MA-12, "RECOMMENDED FLUIDS AND LUBRICANTS" . ● Apply the liquid gasket to the groove on the oil pan mating surface.

E

F

G AEM300

H ●

Allow a 7 mm (0.28 in) clearance around the bolt holes. I

J

K SEM015E

● ●

Be sure the bead of liquid gasket has a diameter of 3.5 - 4.5 mm (0.138 - 0.177 in). Installation must be done within 5 minutes after applying the liquid gasket.

L

M

AEM301

EM-17


OIL PAN [KA24DE] 3.

Install the oil pan. ● Wait at least 30 minutes before refilling the engine oil. ● Tighten the oil pan bolts to specification in numerical order as shown. Oil pan bolts

: 6.4 - 7.5 N·m (0.65 - 0.76 kg-m, 56 - 66 in-lb)

AEM498

4.

Install the remaining parts in the reverse order of removal.

EM-18


TIMING CHAIN [KA24DE]

TIMING CHAIN Components

PFP:13028

A EBS00GSA

EM

C

D

E

F

G

H

I

J

K

L

M

WBIA0214E

1.

Timing chain tensioner (upper)

2.

Cam sprocket

3.

Timing chain (upper)

4.

Water pump

5.

Water pump pulley

6.

Crankshaft pulley

7.

Front oil seal

8.

Front cover

9.

Camshaft sprocket cover

11.

Oil pump drive gear

12. Timing chain (lower)

10. Oil slinger 13. Crankshaft sprocket

14. Chain guide

15. Idler sprocket

16. Chain tension arm

17. Timing chain tensioner (lower)

18. Suitable pin

EM-19


TIMING CHAIN [KA24DE]

WEM135

LIQUID GASKET APPLICATION PLACES

AEM479

Removal

EBS00GSB

CAUTION: ● After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads. ● When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new engine oil. ● Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets and crankshaft pulley. ● Do not spill engine coolant on drive belts.

EM-20


TIMING CHAIN [KA24DE] UPPER TIMING CHAIN 1. 2. 3.

A

Remove the air cleaner assembly. Remove the spark plug wires. Set No.1 piston at TDC on its compression stroke.

EM

C

D

WEM067

4. 5. 6. 7.

Remove the vacuum hoses, electrical harness connectors, and harness clamps. Remove the power steering belt. Remove the power steering pump and position it to one side. Remove the idler pulley and bracket. Remove the rocker cover, loosen and remove the rocker cover bolts in the numerical order as shown.

E

F

G

H

I AEM356

8.

J

Remove the camshaft sprocket cover.

K

L

AEM374

9.

Wipe off the links of the timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the cam sprockets and idler sprocket.

JEM547G

10. Remove cam sprocket bolts, cam sprockets and upper timing chain.

IDLER SPROCKET 1.

Remove upper timing chain.

EM-21

M


TIMING CHAIN [KA24DE] 2.

3.

Refer to EM-21, "UPPER TIMING CHAIN" . If not removing the lower cover, support lower timing chain using a suitable tool to prevent the chain tensioner spring from coming out. NOTE: This step is only to be applied when the lower cover is not being removed. Remove the idler sprocket.

AEM480

LOWER TIMING CHAIN 1. 2. 3. 4.

5. 6. 7. 8.

Drain the coolant by removing the cylinder block drain plug and opening the radiator drain cock. Refer to MA-16, "Changing Engine Coolant" . Drain the engine oil. Refer to MA-20, "Changing Engine Oil" . Remove the intake air duct. Remove the following parts: ● Generator drive belt ● A/C compressor drive belt ● Cooling fan with coupling ● Radiator shroud Remove the A/C compressor without disconnecting the A/C hoses and position it to the side, supporting it with wire. Remove the idler pulley and bracket. Set the No. 1 piston to TDC on its compression stroke. Remove the distributor.

WEM067

EM-22


TIMING CHAIN [KA24DE] 9.

Remove the crankshaft bolt. ● If necessary, remove the rear plact and install Tool to prevent crankshaft rotation. Tool number

:

A

(J-45499)

EM

C LBIA0364E

D

10. Remove the crankshaft pulley with a suitable puller.

E

F

G LEM115

11. Remove the oil pan. Refer to EM-16, "Removal" . 12. Remove the oil pump, distributor drive shaft, and the oil pickup strainer. 13. Remove the front cover. CAUTION: Be careful not to tear or damage the cylinder head gasket. 14. Remove the following parts. ● Release the timing chain tensioner by pushing the piston in and inserting a suitable pin into the pin hole. ● Chain tension arm ● Lower timing chain guide ● Air duct

H

I

J

K

L SEM796E

15. Remove the upper timing chain. Refer to EM-21, "UPPER TIMING CHAIN" .

EM-23

M


TIMING CHAIN [KA24DE] 16. Wipe off the links of the timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the crankshaft sprocket and idler sprocket.

AEM482

17. Remove the lower timing chain, crankshaft sprocket, and idler sprocket.

Inspection

EBS00GSC

Check for cracks and excessive wear at the roller links. Replace the chain if necessary.

AEM403

Installation

EBS00GSD

LOWER TIMING CHAIN 1.

Install crankshaft sprocket. â—? Make sure that the mating marks of crankshaft sprocket face the front of the engine.

SEM205C

2.

Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process. CAUTION: Be careful not to tear or damage the cylinder head gasket.

EM-24


TIMING CHAIN [KA24DE] 3.

Install the chain guide and the chain tension arm. A

EM

C SEM796E

D

4. 5.

Install the lower chain tensioner and remove the pin securing the piston in the tensioner body. Install the front cover and oil seal. ● Using a scraper or other suitable tool remove all traces of liquid gasket from the cylinder block and front cover mating surfaces. ● Install a new crankshaft seal in the front cover. ● Apply a continuous bead of Genuine Silicone RTV Sealant or equivalent, to the front cover. Refer to MA-12, "Recommended Fluids and Lubricants" .

E

F

G SEM715A

H

Install a new front oil seal using a suitable tool. Refer to EM28, "FRONT OIL SEAL" .

I

J

K SEM292D

Apply Genuine Silicone RTV Sealant on the head gasket surface. Refer to GI-42, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . ● Install the front engine cover. Install oil strainer and oil pan. Refer to EM-17, "Installation" . Install the oil pump and distributor drive shaft. ● Make sure the flat side of the distributor drive shaft is facing the engine. Failure to do so will result in the distributor being out of time. Install the crankshaft pulley and crankshaft pulley bolt. Refer to EM-13, "Removal and Installation" . ●

6. 7.

8.

AEM391

EM-25

L

M


TIMING CHAIN [KA24DE] 9.

If installed, remove Tool. Tool number

:

(J-45499)

LBIA0364E

10. Install the rear plate. Rear plate bolts 10 mm hex : 3 - 4 N·m (0.3 - 0.4 kg-m, 32 - 35 in-lb) 14 mm hex : 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)

LBIA0363E

11. Install the A/C compressor and idler pulley bracket. Refer to MTC-67, "Removal and Installation for Compressor" . 12. Install the radiator shroud and cooling fan with coupling. Refer to CO-14, "Removal and Installation" . 13. Install the A/C compressor, generator, and power steering pump drive belts. Refer to MA-15, "Checking Drive Belts" . 14. Install the intake air duct.

IDLER SPROCKET Install the lower timing chain. Refer to EM-24, "LOWER TIMING CHAIN" .

UPPER TIMING CHAIN 1.

Install the lower timing chain and idler sprocket. Refer to EM-24, "LOWER TIMING CHAIN" and EM-26, "IDLER SPROCKET" .

SEM548G

2.

Install the upper timing chain and sprockets, aligning the paint marks made during removal as shown.

SEM549G

EM-26


TIMING CHAIN [KA24DE] 3.

Install the chain tensioner. Remove the pin holding the tensioner piston in the bore of the tensioner. ● Check that the timing chain mating marks are aligned so that the timing chain is correctly installed.

A

EM

C JEM547G

D

4.

5.

6.

Install the camshaft sprocket cover: CAUTION: Do not to tear or damage the cylinder head gasket. Do not let the upper timing chain slip or jump on the sprockets when installing the camshaft sprocket cover. ● Use a scraper to remove all traces of liquid gasket from mating surfaces of the engine block and camshaft sprocket cover. ● Apply liquid gasket on the head gasket surface. ● Apply a continuous bead of liquid gasket to the cylinder head camshaft sprocket cover. Refer to EM-5, "Precautions for Liquid Gasket" . Use Genuine Silicone RTV Sealant or equivalent. Refer to MA-12, "Recommended Fluids and Lubricants" . Install the rocker cover gasket on the rocker cover. ● Apply a continuous bead of liquid gasket to the cylinder head camshaft sprocket cover. Refer to EM-5, "Precautions for Liquid Gasket" . Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" Install the rocker cover. Tighten the bolts in the numerical order as shown. Rocker cover bolts

: 8 - 11 N·m (0.8 - 1.1 kg-m, 69 - 95 in-lb).

E

F

G

H

I

J

K

L AEM357

7.

Install the distributor, align the distributor to the mark as shown. M

WEM067

8.

Install the vacuum hoses, electrical harnesses, connectors, and harness clamps.

EM-27


OIL SEAL [KA24DE]

OIL SEAL Replacement

PFP:00100 EBS00GSE

VALVE OIL SEAL 1. 2. 3.

4.

Remove the rocker cover. Remove the camshaft. Refer to EM-19, "TIMING CHAIN" . Remove valve spring and valve oil seal with Tool or a suitable tool. NOTE: The piston must be at TDC on the compression stroke to prevent the valve from falling into the combustion chamber. Apply engine oil to new valve oil seal and install it with Tool.

SEM289D

The valve oil seal must be installed to specification over the valve stem opening as shown.

SEM290D

FRONT OIL SEAL 1. 2.

Remove radiator shroud. Refer to CO-14, "Components" . Remove the crankshaft bolt. ● If necessary, remove the rear plact and install Tool to prevent crankshaft rotation. Tool number

:

(J-45499)

LBIA0364E

EM-28


OIL SEAL [KA24DE] 3.

Remove the crankshaft pulley with a suitable puller. A

EM

C LEM115

D

4.

Remove front oil seal using suitable tool. CAUTION: Be careful not to scratch the front cover.

E

F

G AEM385

5.

Apply engine oil to new oil seal and install it using a suitable tool.

H

I

J

SEM292D

â—?

K

Install the new oil seal in the direction shown. L

M

SEM715A

6.

Install the crankshaft pulley. Refer to EM-13, "Removal and Installation" .

EM-29


OIL SEAL [KA24DE] 7.

If installed, remove Tool. Tool number

:

(J-45499)

LBIA0364E

8.

Install the rear plate. Rear plate bolts 10 mm hex : 3 - 4 N·m (0.3 - 0.4 kg-m, 32 - 35 in-lb) 14 mm hex : 16 - 22 N·m (1.6 - 2.2 kg-m, 12 - 16 ft-lb)

LBIA0363E

9.

Install radiator shroud. Refer to CO-14, "Components" .

REAR OIL SEAL 1.

2. 3.

Remove the flywheel (M/T) or drive plate (A/T). Refer to MT-10, "Removal and Installation" (FS5W71C), MT-48, "Removal and Installation" (FS5R30A), AT-62, "REMOVAL AND INSTALLATION" (RL4R01A), AT-407, "REMOVAL AND INSTALLATION" (RE4R01A). Remove the rear oil seal retainer. Remove the rear oil seal from the retainer. CAUTION: Be careful not to scratch the rear oil seal retainer.

SEM895A

4.

Apply engine oil to new oil seal and install it using suitable tool.

SEM897A

EM-30


OIL SEAL [KA24DE] ●

Install the new oil seal in the direction shown. A

EM

C SEM715A

D

5.

Install rear oil seal retainer. Rear oil seal retainer bolts

a.

: 6.4 - 7.5 N·m (0.65 - 0.76 kg-m, 56 - 66 in-lb)

E

Before installing rear oil seal retainer, remove all traces of liquid gasket from mating surface using a scraper as shown. Also remove all traces of the old liquid gasket from the mating surface of the cylinder block.

F

G SEM896A

b.

Apply a continuous bead of liquid gasket to mating surface of rear oil seal retainer. Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-42, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" . ● Apply the liquid gasket around the inner side of the bolt holes.

H

I

J

AEM404

K

L

M

EM-31


CYLINDER HEAD [KA24DE]

CYLINDER HEAD On-Vehicle Service

PFP:11041 EBS00GSF

CHECKING COMPRESSION PRESSURE 1. 2. 3. 4. 5. 6. 7. 8. 9.

Warm up the engine. Turn the ignition switch OFF. Release the fuel pressure. Refer to EC-46, "FUEL PRESSURE RELEASE" . Remove all of the spark plugs. ● Clean area around plug with compressed air before removing the spark plug. Disconnect the camshaft position sensor harness connector at the distributor. Remove the fuel injector fuse No. 3 on FUSE BLOCK (J/B) behind the driver side instrument lower panel. Attach a compression tester to the No. 1 cylinder as shown. Depress the accelerator pedal fully to keep the throttle valve wide open. Crank the engine and record the highest gauge indication.

SEM486D

10. Repeat the measurement on each cylinder. ● Always use a fully-charged battery to obtain specified engine speed. Compression Standard Minimum Difference limit between cylinders

: kPa (kg/cm2 , psi)/300 rpm : 1,226 (12.5, 178) : 1,030 (10.5, 149) : 98 (1.0, 14)

11. If the compression in one or more cylinders is low: a. Pour a small amount of engine oil into the cylinders through the spark plug hole. b. Retest the compression. ● If adding oil improves cylinder compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. ● If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. Refer to EM-40, "VALVE DIMENSIONS" , EM-39, "VALVE SEATS" . If valve or valve seat is damaged excessively, replace it. ● If compression in any two cylinders adjacent cylinders is low, and if adding oil does not improve compression, there is leakage past the gasket surface. If so, replace cylinder head gasket. 12. Reinstall the spark plugs, fuel injector fuse, fuel pump fuse, and reconnect camshaft position sensor harness connector at the distributor. 13. Erase the DTC stored in the ECM. Refer to EC-61, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . CAUTION: Always erase the DTC after checking compression.

EM-32


CYLINDER HEAD [KA24DE]

Components

EBS00GSG

A

EM

C

D

E

F

G

H

I

J

K

L

M

WBIA0233E

1.

Oil filler cap

2.

Rocker cover

3.

Camshaft bracket

4.

Intake camshaft

5.

Exhaust camshaft

6.

Adjusting shim

7.

Valve lifter

8.

Valve cotter

9.

Spring retainer

10. Valve spring

11. Spring seat

12. Valve oil seal

13. Intake valve

14. Exhaust valve

15. Cylinder head

16. Cylinder head bolt

17. Valve guide

18. Valve seat

19. Rocker cover gaskets

20. Cylinder head gasket

Removal

EBS00GSH

CAUTION: â—? When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.

EM-33


CYLINDER HEAD [KA24DE] ● ● ●

1.

2.

Apply new engine oil to threads and seat surfaces when installing cylinder head, camshaft sprocket, crankshaft pulley, and camshaft bracket. Attach tags to valve lifters so as not to mix them up. Before removing camshaft and idler sprockets, apply paint marks to them for re-timing. Remove upper timing chain and idler sprocket. Refer to EM-21, "UPPER TIMING CHAIN" and EM-21, "IDLER SPROCKET" . ● For re-timing during cylinder head removal and installation, apply paint marks to the camshaft sprockets, upper timing chain, lower timing chain, and idler sprocket. Remove camshaft brackets and camshafts. Remove the bolts in the reverse order as shown. ● Mark the part with their original position and direction for correct placement for installation.

AEM352

3.

Remove the cylinder head bolts in numerical order as shown. ● Loosen the cylinder head bolts in two or three steps. CAUTION: Remove the bolts in the correct numerical order to avoid warping or cracking the cylinder head.

SEM274D

4.

Remove the cylinder head and cylinder head gasket.

Disassembly 1. 2.

EBS00GSI

Remove the intake manifold and exhaust manifold. Refer to EM-13, "Removal and Installation" . Remove the valve components using Tool as shown. Valve spring compressor

: KV101092S0 (J26336-B)

SEM692D

3.

Remove the valve oil seals using a suitable tool.

Inspection

EBS00GSJ

CYLINDER HEAD DISTORTION 1.

Clean the sealing surface of the cylinder head.

EM-34


CYLINDER HEAD [KA24DE] 2.

Use a reliable straightedge and feeler gauge to check the flatness of cylinder head surface. Check the cylinder head sealing surface flatness along the six positions as shown.

A

Cylinder head surface flatness Limit : 0.1 mm (0.004 in)

EM

If it exceeds the limit, replace or resurface the cylinder head. C SEM294D

D

3.

Resurface the cylinder head as necessary to specification. The limit of cylinder head resurfacing is determined by the cylinder block resurfacing: Amount of cylinder head resurfacing is “A”. Amount of cylinder block resurfacing is “B”. Maximum limit

4.

E

: A + B = 0.2 mm (0.008 in)

After resurfacing, the cylinder head, ● Check that the camshaft rotates freely by hand. If resistance is felt, the cylinder head must be replaced. Nominal cylinder head height

: 126.3 - 126.5 mm (4.972 - 4.980 in)

F

G

CAMSHAFT VISUAL CHECK Check the camshaft for scratches, seizure, and wear.

H

CAMSHAFT RUNOUT 1.

Measure the camshaft runout at the center of the journal. I

Runout (total indicator reading) Standard : less than 0.02 mm (0.0008 in) Limit : 0.04 mm (0.0016 in) 2.

J

If the camshaft runout exceeds the limit, replace the camshaft. K SEM926C

L

CAMSHAFT CAM HEIGHT 1.

Measure camshaft cam height. Standard cam height Intake : 41.755 - 41.945 mm (1.644 - 1.651 in) Exhaust : 41.815 - 42.005 mm (1.646 - 1.654 in) Cam height wear limit Intake & Exhaust : 0.2 mm (0.008 in)

2.

M

If wear is beyond the limit, replace camshaft.

SEM549A

EM-35


CYLINDER HEAD [KA24DE] CAMSHAFT JOURNAL CLEARANCE 1. 2.

Install camshaft bracket and tighten bolts to the specified torque. Measure inner diameter of camshaft bearing. Standard inner diameter No. 1 to No. 5 journals

: 28.000 - 28.025 mm (1.1024 - 1.1033 in)

SEM295D

3.

Measure outer diameter of camshaft journal. Standard outer diameter No. 1 to No. 5 journals

: 27.935 - 27.955 mm (1.0998 - 1.1006 in)

SEM012A

4.

If clearance exceeds the limit, replace camshaft and/or cylinder head. Camshaft journal clearance Standard : 0.045 - 0.090 mm (0.0018 - 0.0035 in) Limit : 0.12 mm (0.0047 in)

CAMSHAFT END PLAY 1. 2.

Install camshaft in cylinder head. Measure camshaft end play. Camshaft end play Standard : 0.070 - 0.148 mm (0.0028 - 0.0058 in) Limit : 0.2 mm (0.008 in)

3. 4.

If end play exceeds the limit, replace camshaft and remeasure camshaft end play. If end play still exceeds the limit after replacing camshaft, replace the cylinder head.

SEM296D

CAMSHAFT SPROCKET RUNOUT 1. 2.

Install sprocket on camshaft. Measure camshaft sprocket runout. Runout (total indicator reading) Limit : 0.15 mm (0.0059 in)

3.

If it exceeds the limit, replace camshaft sprocket.

AEM328

EM-36


CYLINDER HEAD [KA24DE] VALVE GUIDE CLEARANCE 1.

A

Measure valve deflection as shown. Valve and valve guide mostly wear in this direction. Valve deflection limit (dial gauge reading) Intake & Exhaust : 0.2 mm (0.008 in)

EM

C

SEM297D

2. a. b.

If the valve exceeds the deflection limit, check the valve to valve guide clearance: Measure valve stem diameter and valve guide inner diameter. Check that clearance is within specification. Valve to valve guide clearance = valve guide inner diameter - valve stem diameter.

D

E

F

Unit: mm (in) Valve

Standard

Limit

Intake

0.020 - 0.053 (0.0008 - 0.0021)

0.08 (0.0031)

Exhaust

0.040 - 0.073 (0.0016 - 0.0029)

0.1 (0.004)

c. d.

G

H

If the clearance exceeds the limit, replace the valve and remeasure the clearance. If the clearance still exceeds the limit after replacing the valve, replace the valve guide.

I

J

SEM298D

K

VALVE GUIDE REPLACEMENT 1.

To remove the valve guide, heat the cylinder head to 120째 140째C (248째 - 284째F) by soaking in heated oil.

L

M

SEM008A

EM-37


CYLINDER HEAD [KA24DE] 2.

To remove the valve guide, use a press [less than 20 kN (2 metric ton, 2.2 US ton, 2.0 Imp. ton) pressure] or hammer and suitable tool, to slide the valve guide out of the cylinder head.

SEM299D

3.

Ream the cylinder head valve guide hole. Valve guide hole diameter (for service parts) Intake & Exhaust : 11.175 - 11.196 mm (0.4400 - 0.4408 in)

SEM300D

4.

Heat cylinder head to 120° - 140°C (248° - 284°F) in heated oil and press the replacement valve guide into the valve guide hole in the cylinder head. Press the valve guide in to the specified height "L" as shown. Projection “L”

: 13.3 - 13.9 mm (0.524 - 0.547 in)

SEM301D

5.

Ream the new replacement valve guide. Finished size Intake & Exhaust

: 7.000 - 7.018 mm (0.2756 - 0.2763 in)

SEM300D

EM-38


CYLINDER HEAD [KA24DE] VALVE SEATS A

Check valve seats for pitting at contact surface. Resurface or replace if excessively worn. ● Before repairing the valve seats, check the valves and valve guides for wear as shown. If they are worn, replace them. Then resurface the valve seat as necessary.

EM

C

SBIA0322E

Use both hands to resurface the valve seat uniformly using a suitable tool, as shown.

D

E

F

G SEM302D

H

REPLACING VALVE SEAT 1.

Bore out the old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in the cylinder head. Set the machine depth stop to prevent damage.

I

J

K SEM795A

2.

L

Ream the cylinder head valve seat recess. Reaming bore for service valve seat Oversize : 0.5 mm (0.020 in) Intake : 38.000 - 38.016 mm (1.4961 - 1.4967 in) Exhaust : 32.700 - 32.716 mm (1.2874 - 1.2880 in)

3.

M

CAUTION: Use the valve guide center for a reference point for reaming so the valve and valve seat will have the correct fit. Heat the cylinder head to 120° - 140°C (248° - 284°F) in heated oil.

SEM008A

EM-39


CYLINDER HEAD [KA24DE] 4. 5.

Press fit valve seat until it seats on the bottom of the recess. Cut or grind valve seat using suitable tool to the specified dimensions. Seat face “α”

: 45° 15′ - 45° 45′ degrees

Contacting width “W” Intake : 1.48 - 1.63 mm (0.0583 - 0.0642 in) Exhaust : 1.8 - 2.0 mm (0.071 - 0.079 in) SEM892B

6. 7. 8.

After cutting, lap valve seat with abrasive compound. Check the valve seat dimensions. Refer to EM-66, "VALVE SEAT" . Use a depth gauge to measure the distance between the mounting surface of the cylinder head spring seat and the valve stem end. If the distance is shorter than specified, repeat step 5 through 7 above, to adjust it. If it is longer, replace the valve seat with a new one. Valve seat resurface limit - height “L” Intake : 42.02 - 42.52 mm (1.6543 - 1.6740 in) Exhaust : 42.03 - 42.53 mm (1.6547 - 1.6744 in) SEM621F

VALVE DIMENSIONS Check dimensions of each valve. Refer to EM-63, "VALVE" . When valve head has been worn down to less than the margin thickness "T", replace the valve. Do not grind the valve stem more than the grinding limit specification. Margin thickness "T" Valve stem tip grinding limit

: 0.5 mm (0.020 in) : 0.2 mm (0.008 in)

SEM188A

VALVE SPRING Squareness 1.

Measure the spring out-of-square dimension “S” as shown. Out-of-square “S”

2.

: less than 2.2 mm (0.087 in)

If the out-of-square measurement exceeds the limit, replace the spring.

SEM288A

EM-40


CYLINDER HEAD [KA24DE] Pressure 1.

Pressure Standard Limit 2.

A

Check the valve spring pressure at the specified spring height. : N (kg, lb) at height mm (in) : 418.0 (42.6, 93.9) at 29.17 (1.1484) : 393.0 (40.1, 88.4) at 29.17 (1.1484)

EM

If not within specification, replace the spring. C

EM113

D

VALVE LIFTER AND ADJUSTING SHIM 1.

Visually check the valve lifter and adjusting shim contact and sliding surfaces for wear and scratches.

E

F

G

AEM499

2.

H

Check the diameter of the valve lifter as shown. I

J

K AEM502

3.

L

Check the diameter of the valve lifter guide bore as shown.

M

SEM303D

4.

If the measurements exceed the standard diameter or clearance, replace valve lifter or cylinder head as necessary. Valve lifter outer diameter Lifter guide bore diameter Valve lifter to valve lifter guide clearance

: 33.960 - 33.975 mm (1.3370 - 1.3376 in) : 34.000 - 34.021 mm (1.3386 - 1.3394 in) : 0.025 - 0.061 mm (0.0010 - 0.0024 in)

EM-41


CYLINDER HEAD [KA24DE]

Assembly 1.

2.

EBS00GSK

Install valve component parts. ● Always use new valve oil seal. Refer to EM-28, "VALVE OIL SEAL" . ● Before installing valve oil seal, install valve spring seat. ● Install outer valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side. After installing the valve component parts, tap valve stem tip with a plastic hammer to assure a proper fit. SEM638B

Installation 1.

EBS00GSL

Tighten the cylinder head bolts in the numerical order as shown, using the five step procedure:

SEM275D

Cylinder head bolt tightening steps: Step "a" : 29 N·m (3.0 kg-m, 22 ft-lb) Step "b" : 79 N·m (8.1 kg-m, 59 ft-lb) Step "c" : Loosen all bolts completely. Step "d" : 25 - 34 N·m (2.5 - 3.5 kg-m, 18 - 25 ft-lb) Step "e" : 86° - 91° degrees clockwise NOTE: If an angle wrench is not available, mark all of the cylinder head bolts on the side facing engine front. Then turn each cylinder head bolt to the specified angle. 2.

3.

SEM276D

Set camshafts and camshaft brackets. ● Set the dowel pins of both the intake and exhaust camshafts at 12 o'clock position when installing the camshafts. Tighten the camshaft bracket bolts in the order shown using two steps: ● Apply new engine oil to bolt threads and seat surfaces. Camshaft bracket bolt tightening steps Step 1 : 2 N·m (0.2 kg-m, 17 in-lb) Step 2 : 9 - 11.8 N·m (0.92 - 1.2 kg-m, 79.9 - 104.2 in-lb)

AEM352

4.

Install upper timing chain and idler sprocket. Refer to EM-26, "UPPER TIMING CHAIN" , EM-26, "IDLER SPROCKET" .

EM-42


CYLINDER HEAD [KA24DE]

Valve Clearance

EBS00GSM

A

CHECKING Check valve clearance while engine is warm but not running. 1. Remove the following parts: ● Rocker cover ● All spark plugs 2. Set No. 1 cylinder at TDC on its compression stroke. ● Align pointer with TDC mark on crankshaft pulley. ● Check that valve lifters on No. 1 cylinder are loose and valve lifters on No. 4 are tight. If not, turn crankshaft one revolution (360°) and align as above.

EM

C

D

E

WEM068

3.

F

Check only those valves as shown. G

H

I AEM382

4.

J

Using a feeler gauge, measure clearance between valve lifter and camshaft. ● Record any valve clearance measurements which are out of specification. They will be used later to determine the required replacement adjusting shim.

K

Valve clearance (hot) Intake : 0.31 - 0.39 mm (0.012 - 0.015 in) Exhaust : 0.39 - 0.47 mm (0.015 - 0.019 in)

L

SEM304D

5. 6.

Turn crankshaft one revolution (360° degrees) and align mark on crankshaft pulley with pointer. Check only those valves as shown. ● Use the same procedure as described in step 4.

AEM383

7.

If all of the valve clearances are within specification, install the following parts: ● Rocker cover ● All spark plugs

EM-43

M


CYLINDER HEAD [KA24DE] ADJUSTING CAUTION: Adjust the valve clearance while engine is cold. 1. Turn the crankshaft to position the camshaft lobe on the valve that must be adjusted upward. 2. Place Tool (A) around camshaft as shown. CAUTION: Before placing Tool (A), rotate notch toward the center of the cylinder head as shown, to simplify the shim removal. 3. Rotate Tool (A) so that lifter is pushed down. CAUTION: Be careful not to damage the cam surface with Tool (A).

SEM515EA

4.

5.

Place Tool (B) between camshaft and the edge of the valve lifter to retain valve lifter. CAUTION: â—? Tool (B) must be placed as close to camshaft bracket as possible. â—? Be careful not to damage cam surface with Tool (B). Remove Tool (A).

SEM516EA

6.

Rotate the adjusting shim until a hole is visible. Blow air into the hole to separate the adjusting shim from the valve lifter.

AEM447

7.

Remove the adjusting shim using a small screwdriver and a magnetic finger or suitable tool.

SEM517EA

EM-44


CYLINDER HEAD [KA24DE] 8. a.

Calculate the replacement adjusting shim size. Using a micrometer to determine the thickness of the removed adjusting shim.

A

EM

C SEM145D

D

b.

Calculate the thickness of the new adjusting shim so that the valve clearance comes within the specified values. N = Thickness of new shim R = Thickness of removed shim M = Measured valve clearance Intake and exhaust shim calculation

c.

: N = R + [M − 0.37 mm (0.0146 in)]

E

F

Select a new adjusting shim with the thickness as close as possible to the calculated value "N". Refer to EM-65, "AVAILABLE SHIMS" . NOTE: Shims are available in thicknesses from 1.96 - 2.68 mm (0.0772 - 0.1055 in), in increments of 0.02 mm (0.0008 in). The adjusting shim thickness is stamped on the bottom of the adjusting shim as shown.

G

H

I SEM308D

9.

Install the new adjusting shim using a suitable tool. CAUTION: Install the adjusting shim with the surface on which the thickness is stamped facing down.

J

K

L

SEM518EA

10. 11. 12. 13.

Place Tool (A) as described in steps 2 through 4. Remove Tool (B). Remove Tool (A). Recheck the valve clearance. Refer to EM-43, "Valve Clearance" .

EM-45

M


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2004 nissan frontier service repair manual  
2004 nissan frontier service repair manual  
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