Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 2003-2005 Approved Nissan Frontier 2005 EM
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B ENGINE
A
SECTION
ENGINE MECHANICAL
EM EM
C
D
E
CONTENTS
QR INTAKE MANIFOLD ................................................ 17 . F
Removal and Installation ....................................... 17 .
PRECAUTIONS ......................................................... 5 . REMOVAL .......................................................... 17 .
Precautions for Drain Engine Coolant and Engine INSTALLATION .................................................. 18 . G
Oil ............................................................................ 5
. INSPECTION AFTER INSTALLATION ............... 19 .
Precautions for Disconnecting Fuel Piping ............. 5 . EXHAUST MANIFOLD AND THREE WAY CATA-
Precautions for Removal and Disassembly ............ 5 . LYST ......................................................................... 20
.
Precautions for Inspection, Repair and Replace- H
Removal and Installation ....................................... 20 .
ment ........................................................................ 5
. REMOVAL .......................................................... 20 .
Precautions for Assembly and Installation .............. 5 . INSPECTION AFTER REMOVAL ...................... 21 .
Parts Requiring Angle Tightening ............................ 5 . INSTALLATION .................................................. 21 . I
Precautions for Liquid Gasket ................................. 6 . OIL PAN ................................................................... 22
.
REMOVAL OF LIQUID GASKET SEALING ......... 6 . Removal and Installation ....................................... 22 .
LIQUID GASKET APPLICATION PROCEDURE 6 ..... REMOVAL .......................................................... 22 . J
PREPARATION .......................................................... 7 . INSTALLATION .................................................. 23 .
Special Service Tools .............................................. 7 . INSPECTION AFTER INSTALLATION ............... 23 .
Commercial Service Tools ....................................... 9 . IGNITION COIL ........................................................ 25 .
NOISE, VIBRATION AND HARSHNESS (NVH) K
Removal and Installation ....................................... 25 .
TROUBLESHOOTING ..............................................11 . REMOVAL .......................................................... 25 .
NVH Troubleshooting -- Engine Noise ..................11 . INSTALLATION .................................................. 25 .
Use the Chart Below to Help You Find the Cause SPARK PLUG (PLATINUM-TIPPED TYPE) ............ 26 . L
of the Symptom. .................................................... 12 . Removal and Installation ....................................... 26 .
DRIVE BELTS .......................................................... 13 . REMOVAL .......................................................... 26 .
Checking Drive Belt ............................................... 13 . INSPECTION AFTER REMOVAL ...................... 26 . M
Tension Adjustment ............................................... 13 . INSTALLATION .................................................. 27 .
Removal and Installation ....................................... 13 . FUEL INJECTOR AND FUEL TUBE ....................... 28 .
REMOVAL .......................................................... 13 . Removal and Installation ....................................... 28 .
INSTALLATION .................................................. 14 . REMOVAL .......................................................... 28 .
Removal and Installation of Drive Belt Auto-Ten- INSTALLATION .................................................. 30 .
sioner .................................................................... 14
. INSPECTION AFTER INSTALLATION ............... 32 .
REMOVAL .......................................................... 14 . ROCKER COVER .................................................... 33 .
INSTALLATION .................................................. 14 . Removal and Installation ....................................... 33 .
AIR CLEANER AND AIR DUCT .............................. 15 . REMOVAL .......................................................... 33 .
Removal and Installation ....................................... 15 . INSTALLATION .................................................. 34 .
REMOVAL .......................................................... 15 . CAMSHAFT ............................................................. 35 .
INSPECTION AFTER REMOVAL ...................... 15 . Removal and Installation ....................................... 35 .
INSTALLATION .................................................. 15 . REMOVAL .......................................................... 35 .
Changing Air Cleaner Filter ................................... 16 . INSPECTION AFTER REMOVAL ...................... 37 .
REMOVAL .......................................................... 16 . INSTALLATION .................................................. 40 .
INSTALLATION .................................................. 16 .
Revision: November 2005 EM-1 2005 Frontier
INSPECTION AFTER INSTALLATION ............... 43 . HOW TO SELECT MAIN BEARING ...................87 .
Valve Clearance ..................................................... 44. Inspection After Disassembly .................................91 .
INSPECTION ...................................................... 44 . CRANKSHAFT END PLAY .................................91 .
ADJUSTMENT ................................................... 45 . CONNECTING ROD SIDE CLEARANCE ..........91 .
TIMING CHAIN ......................................................... 47 . PISTON TO PISTON PIN OIL CLEARANCE ......91 .
Removal and Installation ....................................... 47 . PISTON RING SIDE CLEARANCE ....................92 .
REMOVAL .......................................................... 48 . PISTON RING END GAP ...................................92 .
INSPECTION AFTER REMOVAL ....................... 51 . CONNECTING ROD BEND AND TORSION ......93 .
INSTALLATION ................................................... 51 . CONNECTING ROD BIG END DIAMETER .......93 .
INSPECTION AFTER INSTALLATION ............... 55 . CONNECTING ROD BUSHING OIL CLEAR-
OIL SEAL ................................................................. 56
. ANCE ..................................................................93
.
Removal and Installation of Valve Oil Seal ............ 56 . CYLINDER BLOCK DISTORTION .....................94 .
REMOVAL .......................................................... 56 . MAIN BEARING HOUSING INNER DIAMETER...95
INSTALLATION ................................................... 56 . PISTON TO CYLINDER BORE CLEARANCE ...95
Removal and Installation of Front Oil Seal ............ 56 . CRANKSHAFT MAIN JOURNAL DIAMETER ....96 .
REMOVAL .......................................................... 56 . CRANKSHAFT PIN JOURNAL DIAMETER .......97 .
INSTALLATION ................................................... 57 . OUT-OF-ROUND AND TAPER OF CRANK-
Removal and Installation of Rear Oil Seal ............. 57 . SHAFT ................................................................97
.
REMOVAL .......................................................... 57 . CRANKSHAFT RUNOUT ...................................97 .
INSTALLATION ................................................... 57 . CONNECTING ROD BEARING OIL CLEAR-
CYLINDER HEAD .................................................... 59 . ANCE ..................................................................97
.
On-Vehicle Service ................................................ 59 . MAIN BEARING OIL CLEARANCE ....................98 .
CHECKING COMPRESSION PRESSURE ........ 59 . MAIN BEARING CRUSH HEIGHT .....................99 .
Removal and Installation ....................................... 60 . CONNECTING ROD BEARING CRUSH
REMOVAL .......................................................... 60 . HEIGHT ..............................................................99
.
INSPECTION AFTER REMOVAL ....................... 61 . LOWER CYLINDER BLOCK MOUNTING BOLT
INSTALLATION ................................................... 62 . OUTER DIAMETER ............................................99 .
INSPECTION AFTER INSTALLATION ............... 62 . CONNECTING ROD BOLT OUTER DIAMETER...99
Disassembly and Assembly ................................... 63 . FLYWHEEL DEFLECTION (M/T MODELS) ..... 100 .
DISASSEMBLY .................................................. 63 . MOVEMENT AMOUNT OF FLYWHEEL (M/T
ASSEMBLY ........................................................ 64 . MODELS) .......................................................... 100
.
Inspection After Disassembly ................................ 66 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 101 .
VALVE DIMENSIONS ......................................... 66 . Standard and Limit ............................................... 101.
VALVE GUIDE CLEARANCE ............................. 66 . GENERAL SPECIFICATIONS .......................... 101 .
VALVE GUIDE REPLACEMENT ........................ 66 . DRIVE BELT ..................................................... 101.
VALVE SEAT CONTACT .................................... 68 . EXHAUST MANIFOLD AND THREE WAY CAT-
VALVE SEAT REPLACEMENT .......................... 68 . ALYST ASSEMBLY ........................................... 101 .
VALVE SPRING SQUARENESS ........................ 69 . SPARK PLUG ................................................... 101 .
VALVE SPRING DIMENSIONS AND VALVE CYLINDER HEAD ............................................. 101 .
SPRING PRESSURE LOAD .............................. 69 . VALVE ............................................................... 102
.
ENGINE ASSEMBLY ............................................... 70 . CAMSHAFT AND CAMSHAFT BEARING ........ 106 .
Removal and Installation ....................................... 70 . CYLINDER BLOCK ........................................... 106 .
REMOVAL .......................................................... 71 . PISTON, PISTON RING AND PISTON PIN ..... 108 .
INSTALLATION ................................................... 72 . CONNECTING ROD ......................................... 109 .
INSPECTION AFTER INSTALLATION ............... 72 . CRANKSHAFT .................................................. 109 .
CYLINDER BLOCK .................................................. 74 . MAIN BEARING ................................................ 111 .
Disassembly and Assembly ................................... 74 . CONNECTING ROD BEARING ........................ 112 .
DISASSEMBLY .................................................. 75 .
ASSEMBLY ........................................................ 79 . VQ
How to Select Piston and Bearing ......................... 84 .
DESCRIPTION ................................................... 84 . PRECAUTIONS ...................................................... 113 .
HOW TO SELECT PISTON ................................ 84 . Precautions for Drain Engine Coolant .................. 113 .
HOW TO SELECT CONNECTING ROD BEAR- Precautions for Disconnecting Fuel Piping .......... 113 .
ING ..................................................................... 85
. Precautions for Removal and Disassembly ......... 113 .
Precautions for Inspection, Repair and Replace-
ment ..................................................................... 113
.
Precautions for Assembly and Installation ........... 113 .
Revision: November 2005 EM-2 2005 Frontier
Parts Requiring Angle Tightening .........................113 . OIL PAN AND OIL STRAINER .............................. 135 .
Precautions for Liquid Gasket ..............................114 . Removal and Installation ..................................... 135 . A
REMOVAL OF LIQUID GASKET SEALING ......114 . REMOVAL (LOWER) ........................................ 135 .
LIQUID GASKET APPLICATION PROCEDURE ..114 INSPECTION AFTER REMOVAL .................... 136 .
PREPARATION .......................................................115 . INSTALLATION (LOWER) ................................ 136 . EM
Special Service Tools ...........................................115 . INSPECTION AFTER INSTALLATION ............. 137 .
Commercial Service Tools ....................................117 . REMOVAL (UPPER) ........................................ 137 .
NOISE, VIBRATION AND HARSHNESS (NVH) INSPECTION AFTER REMOVAL .................... 138 .
TROUBLESHOOTING ............................................119 . INSTALLATION (UPPER) ................................. 138 . C
NVH Troubleshooting --Engine Noise .................119 . INSPECTION AFTER INSTALLATION ............. 139 .
Use the Chart Below to Help You Find the Cause IGNITION COIL ...................................................... 140
.
of the Symptom ................................................... 120 . Removal and Installation ..................................... 140 . D
ENGINE ROOM COVER ....................................... 121 . REMOVAL (LEFT BANK) ................................. 140 .
Removal and Installation ..................................... 121 . INSTALLATION (LEFT BANK) ......................... 140 .
REMOVAL ........................................................ 121 . REMOVAL (RIGHT BANK) ............................... 140 . E
INSTALLATION ................................................ 121 . INSTALLATION (RIGHT BANK) ....................... 140 .
DRIVE BELTS ........................................................ 122 . SPARK PLUG (PLATINUM-TIPPED TYPE) .......... 141 .
Checking Drive Belts ........................................... 122 . Removal and Installation ..................................... 141 .
Tension Adjustment ............................................. 122 . REMOVAL ........................................................ 141. F
Removal and Installation ..................................... 122 . INSPECTION AFTER REMOVAL .................... 141 .
DRIVE BELT .................................................... 122 . INSTALLATION ................................................ 142 .
INSTALLATION ................................................ 123 . FUEL INJECTOR AND FUEL TUBE ..................... 143 . G
Drive Belt Auto-Tensioner and Idler Pulley .......... 123 . Removal and Installation ..................................... 143 .
REMOVAL ........................................................ 123 . REMOVAL ........................................................ 143.
INSTALLATION ................................................ 123 . INSTALLATION ................................................ 146 . H
AIR CLEANER AND AIR DUCT ............................ 124 . INSPECTION AFTER INSTALLATION ............. 148 .
Removal and Installation ..................................... 124 . ROCKER COVER .................................................. 149 .
REMOVAL ........................................................ 124 . Removal and Installation ..................................... 149 .
I
INSPECTION AFTER REMOVAL .................... 124 . REMOVAL (LEFT BANK) ................................. 149 .
INSTALLATION ................................................ 124 . INSTALLATION (LEFT BANK) ......................... 150 .
Changing Air Cleaner Filter ................................. 124 . REMOVAL (RIGHT BANK) ............................... 151 .
REMOVAL ........................................................ 124 . INSTALLATION (RIGHT BANK) ....................... 152 . J
INSTALLATION ................................................ 124 . FRONT TIMING CHAIN CASE .............................. 154 .
INTAKE MANIFOLD COLLECTOR ....................... 125 . Removal and Installation ..................................... 154 .
Removal and Installation ..................................... 125 . REMOVAL ........................................................ 154. K
REMOVAL ........................................................ 126 . INSTALLATION ................................................ 158 .
INSTALLATION ................................................ 127 . INSPECTION AFTER INSTALLATION ............. 161 .
INTAKE MANIFOLD .............................................. 128 . TIMING CHAIN ....................................................... 163
.
L
Removal and Installation ..................................... 128 . Removal and Installation ..................................... 163 .
REMOVAL ........................................................ 128 . REMOVAL ........................................................ 164.
INSPECTION AFTER REMOVAL .................... 128 . INSPECTION AFTER REMOVAL .................... 171 .
INSTALLATION ................................................ 129 . INSTALLATION ................................................ 172 . M
EXHAUST MANIFOLD AND THREE WAY CATA- INSPECTION AFTER INSTALLATION ............. 182 .
LYST ...................................................................... 130
. CAMSHAFT ........................................................... 183
.
Removal and Installation ..................................... 130 . Removal and Installation ..................................... 183 .
REMOVAL (LEFT BANK) ................................. 130 . REMOVAL ........................................................ 184.
INSPECTION AFTER REMOVAL .................... 131 . INSPECTION AFTER REMOVAL .................... 185 .
INSTALLATION (LEFT BANK) ......................... 132 . INSTALLATION ................................................ 188 .
REMOVAL (RIGHT BANK) .............................. 133 . INSPECTION AFTER INSTALLATION ............. 191 .
INSPECTION AFTER REMOVAL .................... 133 . Valve Clearance .................................................. 192
.
INSTALLATION (RIGHT BANK) ....................... 134 . INSPECTION ................................................... 192 .
ADJUSTMENT ................................................. 195 .
OIL SEAL ............................................................... 197
.
Removal and Installation of Valve Oil Seal .......... 197 .
REMOVAL ........................................................ 197.
INSTALLATION ................................................ 197 .
Removal and Installation of Front Oil Seal .......... 198 .
REMOVAL ........................................................ 198.
Revision: November 2005 EM-3 2005 Frontier
INSTALLATION ................................................. 198 . ANCE ................................................................ 234
.
Removal and Installation of Rear Oil Seal ........... 199 . CYLINDER BLOCK DISTORTION ................... 235 .
REMOVAL ........................................................ 199 . MAIN BEARING HOUSING INNER DIAMETER.236
INSTALLATION ................................................. 199 . PISTON TO CYLINDER BORE CLEARANCE . 236
CYLINDER HEAD .................................................. 201 . CRANKSHAFT MAIN JOURNAL DIAMETER .. 237 .
On-Vehicle Service .............................................. 201 . CRANKSHAFT PIN JOURNAL DIAMETER ..... 238 .
CHECKING COMPRESSION PRESSURE ...... 201 . CRANKSHAFT OUT-OF-ROUND AND TAPER.238
Removal and Installation ..................................... 202 . CRANKSHAFT RUNOUT ................................. 238 .
REMOVAL ........................................................ 202 . CONNECTING ROD BEARING OIL CLEAR-
INSPECTION AFTER REMOVAL ..................... 203 . ANCE ................................................................ 238
.
INSTALLATION ................................................. 204 . MAIN BEARING OIL CLEARANCE .................. 239 .
INSPECTION AFTER INSTALLATION ............. 205 . CRUSH HEIGHT OF MAIN BEARING ............. 240 .
Disassembly and Assembly ................................. 206 . CRUSH HEIGHT OF CONNECTING ROD
DISASSEMBLY ................................................ 206 . BEARING .......................................................... 240
.
ASSEMBLY ...................................................... 207 . LOWER CYLINDER BLOCK BOLT OUTER
Inspection After Disassembly .............................. 208 . DIAMETER ....................................................... 240.
VALVE DIMENSIONS ....................................... 208 . CONNECTING ROD BOLT OUTER DIAMETER.241
VALVE GUIDE CLEARANCE ........................... 208 . FLYWHEEL DEFLECTION (M/T MODELS) ..... 241 .
VALVE GUIDE REPLACEMENT ...................... 209 . MOVEMENT AMOUNT OF FLYWHEEL (M/T
VALVE SEAT CONTACT .................................. 210 . MODELS) .......................................................... 241
.
VALVE SEAT REPLACEMENT ........................ 210 . DRIVE PLATE ................................................... 242 .
VALVE SPRING SQUARENESS ...................... 211 . OIL JET ............................................................. 242
.
VALVE SPRING DIMENSIONS AND VALVE OIL JET RELIEF VALVE ................................... 242 .
SPRING PRESSURE LOAD ............................ 212 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 243 .
ENGINE ASSEMBLY ............................................. 213 . Standard and Limit ............................................... 243.
Removal and Installation ..................................... 213 . GENERAL SPECIFICATIONS .......................... 243 .
REMOVAL ........................................................ 214 . DRIVE BELT ..................................................... 244.
INSTALLATION ................................................. 215 . INTAKE MANIFOLD COLLECTOR, INTAKE
INSPECTION AFTER INSTALLATION ............. 215 . MANIFOLD AND EXHAUST MANIFOLD ......... 244 .
CYLINDER BLOCK ................................................ 216 . SPARK PLUG ................................................... 244 .
Disassembly and Assembly ................................. 216 . CAMSHAFT AND CAMSHAFT BEARING ........ 245 .
DISASSEMBLY ................................................ 217 . CYLINDER HEAD ............................................. 247 .
ASSEMBLY ...................................................... 221 . CYLINDER BLOCK ........................................... 250 .
How to Select Piston and Bearing ....................... 227 . PISTON, PISTON RING AND PISTON PIN ..... 251 .
DESCRIPTION ................................................. 227 . CONNECTING ROD ......................................... 252 .
HOW TO SELECT PISTON .............................. 227 . CRANKSHAFT .................................................. 253 .
HOW TO SELECT CONNECTING ROD BEAR- MAIN BEARING ................................................ 254 .
ING ................................................................... 228
. CONNECTING ROD BEARING ........................ 255 .
HOW TO SELECT MAIN BEARING ................. 229 .
Inspection After Disassembly .............................. 232 .
CRANKSHAFT END PLAY ............................... 232 .
CONNECTING ROD SIDE CLEARANCE ........ 232 .
PISTON TO PISTON PIN OIL CLEARANCE ... 232 .
PISTON RING SIDE CLEARANCE .................. 233 .
PISTON RING END GAP ................................. 233 .
CONNECTING ROD BEND AND TORSION .... 234 .
CONNECTING ROD BIG END DIAMETER ..... 234 .
CONNECTING ROD BUSHING OIL CLEAR-
Revision: November 2005 EM-4 2005 Frontier
PRECAUTIONS
[QR]
PRECAUTIONS PFP:00001
A
Precautions for Drain Engine Coolant and Engine Oil EBS00NGC
Drain engine coolant and engine oil when the engine is cooled.
EM
Precautions for Disconnecting Fuel Piping EBS00NGD
G Before starting work, make sure no fire or spark producing items are in the work area.
G Release fuel pressure before disassembly. C
G After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS00NGE
D
G When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
G Exercise maximum care to avoid damage to mating or sliding surfaces. E
G Cover openings of engine system with a tape or the equivalent, if necessary, to seal out foreign materials.
G Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
G When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally F
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be
used where noted in the step.
Precautions for Inspection, Repair and Replacement EBS00NGF G
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
H
Precautions for Assembly and Installation EBS00NGG
G Use torque wrench to tighten bolts or nuts to specification.
G When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the I
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
G Replace with new gasket, packing, oil seal or O-ring. J
G Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
make sure that dowel pins are installed in the original position.
G Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for K
any restriction and blockage.
G Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well. L
G Release air within route when refilling after draining engine coolant.
G Before starting the engine, apply fuel pressure to fuel lines with turning ignition switch "ON" (with the
engine stopped). Then make sure there are no leaks at fuel line connections. M
G After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Parts Requiring Angle Tightening EBS00NGH
G For the final tightening of the following engine parts use Tool:
Tool number : KV10112100 (BT-8653-A)
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