Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 1998-2002 Approved Nissan Frontier 2002 EM
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ENGINE MECHANICAL GI
SECTION EM MA
LC
EC
CONTENTS FE
KA24DE Removal.....................................................................30
CL
Installation..................................................................31
PRECAUTIONS ...............................................................4
Disassembly...............................................................31 MT
Supplemental Restraint System (SRS) AIR
Inspection...................................................................31
BAG and SEAT BELT PRE-TENSIONER...............4
CYLINDER HEAD DISTORTION ...............................31
Parts Requiring Angular Tightening.............................5 CAMSHAFT VISUAL CHECK ....................................32 AT
Liquid Gasket Application Procedure ..........................5 CAMSHAFT RUNOUT ..............................................32
PREPARATION ...............................................................6 CAMSHAFT CAM HEIGHT .......................................32
Special Service Tools ..................................................6 CAMSHAFT JOURNAL CLEARANCE ........................32 TF
Commercial Service Tools ...........................................8 CAMSHAFT END PLAY............................................33
NOISE, VIBRATION AND HARSHNESS (NVH) CAMSHAFT SPROCKET RUNOUT ...........................33
TROUBLESHOOTING ...................................................10 VALVE GUIDE CLEARANCE ....................................33 PD
NVH Troubleshooting Chart - Engine Noise .............11 VALVE GUIDE REPLACEMENT ................................34
OUTER COMPONENT PARTS .....................................12 VALVE SEATS .........................................................35
Removal and Installation ...........................................12 REPLACING VALVE SEAT FOR SERVICE PARTS ....35 AX
VALVE DIMENSIONS ...............................................36
MEASUREMENT OF COMPRESSION PRESSURE ....15
VALVE SPRING .......................................................37
OIL PAN.........................................................................16 SU
VALVE LIFTER AND VALVE SHIM ............................37
Components...............................................................16 Assembly ...................................................................38
Removal.....................................................................16 Valve Clearance.........................................................38
Installation..................................................................17 CHECKING .............................................................38
BR
TIMING CHAIN ..............................................................18 ADJUSTING ............................................................39
Components...............................................................18 ENGINE ASSEMBLY.....................................................41
LIQUID GASKET APPLICATION PLACES..................19
ST
Removal and Installation ...........................................41
Removal.....................................................................20 REMOVAL ...............................................................42
UPPER TIMING CHAIN ............................................20 INSTALLATION........................................................43
IDLER SPROCKET ..................................................21
RS
CYLINDER BLOCK .......................................................44
LOWER TIMING CHAIN ...........................................21 Components...............................................................44
Inspection...................................................................22 Removal and Installation ...........................................45 BT
Installation..................................................................23 Disassembly...............................................................45
LOWER TIMING CHAIN ...........................................23
PISTON AND CRANKSHAFT ....................................45
IDLER SPROCKET ..................................................24 HA
Inspection...................................................................45
UPPER TIMING CHAIN ............................................24
PISTON AND PISTON PIN CLEARANCE ..................45
OIL SEAL.......................................................................26
PISTON RING SIDE CLEARANCE ............................46
Replacement..............................................................26 PISTON RING END GAP..........................................46 SC
VALVE OIL SEAL .....................................................26 CONNECTING ROD BEND AND TORSION ...............46
OIL SEAL INSTALLING DIRECTION .........................26 CYLINDER BLOCK DISTORTION AND WEAR ...........47
FRONT OIL SEAL ....................................................26 PISTON-TO-BORE CLEARANCE ..............................47
EL
REAR OIL SEAL ......................................................27 CRANKSHAFT.........................................................48
CYLINDER HEAD..........................................................29 BEARING CLEARANCE ...........................................49
Components...............................................................29 IDX
CONTENTS (Cont'd)
CONNECTING ROD BUSHING CLEARANCE OIL PAN.........................................................................79
(SMALL END) ..........................................................51 Removal.....................................................................79
REPLACEMENT OF CONNECTING ROD Installation..................................................................80
BUSHING (SMALL END) ..........................................51 TIMING BELT ................................................................82
FLYWHEEL RUNOUT ..............................................52
Components...............................................................82
Assembly ...................................................................52
Removal.....................................................................83
PISTON ..................................................................52
Inspection...................................................................84
CRANKSHAFT.........................................................53
BELT TENSIONER AND TENSIONER SPRING ..........85
REPLACING PILOT BUSHING ..................................54
Installation..................................................................85
SERVICE DATA AND SPECIFICATIONS (SDS) .........55
Tension Adjustment....................................................86
General Specifications...............................................55
AFTER BELT REPLACEMENT..................................86
COMPRESSION PRESSURE ...................................55
AFTER ENGINE OVERHAUL OR ENGINE
Cylinder Head ............................................................55
REASSEMBLY (WITH ROCKER COVERS
Valve ..........................................................................56 REMOVED) .............................................................87
VALVE ....................................................................56
OIL SEAL.......................................................................89
VALVE SPRING .......................................................56
Replacement..............................................................89
VALVE GUIDE .........................................................57
VALVE OIL SEAL .....................................................89
VALVE LIFTER ........................................................57
OIL SEAL INSTALLING DIRECTION .........................89
VALVE CLEARANCE ADJUSTMENT .........................57
CAMSHAFT OIL SEAL .............................................90
AVAILABLE SHIMS ..................................................58
FRONT OIL SEAL ....................................................90
VALVE SEAT ...........................................................59
REAR OIL SEAL ......................................................90
Cylinder Block............................................................60
CYLINDER HEAD..........................................................91
Camshaft and Camshaft Bearing ..............................61
Components...............................................................91
Piston, Piston Ring and Piston pin............................62
Removal.....................................................................92
PISTON ..................................................................62
Disassembly...............................................................94
PISTON PIN ............................................................62
PISTON RING .........................................................62 Inspection...................................................................95
Connecting Rod .........................................................63 CYLINDER HEAD DISTORTION ...............................95
CAMSHAFT VISUAL CHECK ....................................95
Crankshaft..................................................................63
CAMSHAFT RUNOUT ..............................................95
Bearing Clearance .....................................................64
CAMSHAFT CAM HEIGHT .......................................95
Available Main Bearing..............................................64 CAMSHAFT JOURNAL CLEARANCE ........................95
STANDARD .............................................................64 CAMSHAFT END PLAY............................................96
UNDERSIZE (SERVICE) ..........................................64 CAMSHAFT SPROCKET RUNOUT ...........................96
Available Connecting Rod Bearing............................64 VALVE GUIDE CLEARANCE ....................................96
STANDARD .............................................................64 VALVE GUIDE REPLACEMENT ................................97
UNDERSIZE (SERVICE) ..........................................64 VALVE SEATS .........................................................98
Miscellaneous Components.......................................65 REPLACING VALVE SEAT FOR SERVICE PARTS ....99
VALVE DIMENSIONS ...............................................99
VG33E AND VG33ER VALVE SPRING .....................................................100
ROCKER SHAFT AND ROCKER ARM ....................101
PRECAUTIONS .............................................................66 HYDRAULIC VALVE LIFTER ..................................101
Supplemental Restraint System (SRS) AIR Assembly .................................................................101
BAG and SEAT BELT PRE-TENSIONER.............66 Installation................................................................102
Parts Requiring Angular Tightening...........................67 SUPERCHARGER .......................................................107
Liquid Gasket Application Procedure ........................67 Components.............................................................107
PREPARATION .............................................................68 Removal...................................................................108
Special Service Tools ................................................68 Inspection.................................................................109
Commercial Service Tools .........................................70 SUPERCHARGER FLANGE ...................................109
NOISE, VIBRATION AND HARSHNESS (NVH) ROTOR SYSTEM ..................................................109
TROUBLESHOOTING ...................................................72 SUPERCHARGER BYPASS VALVE ACTUATOR .....110
NVH Troubleshooting Chart - Engine Noise .............73 Installation................................................................110
OUTER COMPONENT PARTS .....................................74 ENGINE ASSEMBLY................................................... 111
Removal and Installation ...........................................74 Removal and Installation ......................................... 111
MEASUREMENT OF COMPRESSION PRESSURE ....77 REMOVAL .............................................................112
CYLINDER BLOCK .....................................................114
EM-2
CONTENTS (Cont'd)
Components.............................................................114 VALVE ..................................................................127 GI
Removal and Installation .........................................115 VALVE SPRING .....................................................128
Disassembly.............................................................115 HYDRAULIC VALVE LIFTER ..................................128
PISTON AND CRANKSHAFT ..................................115 VALVE GUIDE .......................................................128 MA
Inspection.................................................................116 ROCKER SHAFT AND ROCKER ARM ....................128
PISTON AND PISTON PIN CLEARANCE ................116 Valve Seat................................................................129
PISTON RING SIDE CLEARANCE ..........................116 INTAKE VALVE SEAT ............................................129
PISTON RING END GAP........................................117 EXHAUST VALVE SEAT.........................................130
CONNECTING ROD BEND AND TORSION .............117 Camshaft and Camshaft Bearing ............................131
CYLINDER BLOCK DISTORTION AND WEAR .........117 Cylinder Block..........................................................132 LC
PISTON-TO-BORE CLEARANCE ............................118 Piston, Piston Ring and Piston Pin .........................133
CRANKSHAFT.......................................................119 AVAILABLE PISTON ..............................................133
BEARING CLEARANCE .........................................120 PISTON RING .......................................................133
EC
CONNECTING ROD BUSHING CLEARANCE PISTON PIN ..........................................................134
(SMALL END) ........................................................122 Connecting Rod .......................................................134
REPLACEMENT OF CONNECTING ROD
FE
Crankshaft................................................................134
BUSHING (SMALL END) ........................................123 Available Main Bearing............................................135
FLYWHEEL/DRIVE PLATE RUNOUT ......................123 NO. 1 MAIN BEARING ...........................................135 CL
Assembly .................................................................123 NO. 2 AND 3 MAIN BEARING ................................135
PISTON ................................................................123 NO. 4 MAIN BEARING ...........................................135
CRANKSHAFT.......................................................124 UNDER SIZE .........................................................135 MT
REPLACING PILOT BUSHING (M/T) OR PILOT Available Connecting Rod Bearing..........................136
CONVERTER (A/T) ................................................125 CONNECTING ROD BEARING UNDERSIZE ...........136
SERVICE DATA AND SPECIFICATIONS (SDS) .......126 Miscellaneous Components.....................................136 AT
General Specifications.............................................126 BEARING CLEARANCE .........................................136
Cylinder Head ..........................................................127
Valve ........................................................................127 TF
PD
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
EM-3
PRECAUTIONS KA24DE
Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
Supplemental Restraint System (SRS) "AIR
BAG" and "SEAT BELT PRE-TENSIONER" NEEM0125
The Supplemental Restraint System such as "AIR BAG" and "SEAT
BELT PRE-TENSIONER" used along with a seat belt, helps to
reduce the risk or severity of injury to the driver and front passen-
ger in a frontal collision. The Supplemental Restraint System con-
sists of a driver air bag module (located in the center of the steer-
ing wheel), a front passenger air bag module (located on the instru-
ment panel on the passenger side), seat belt pre-tensioners, a
diagnosis sensor unit, warning lamp, wiring harness, and spiral
cable.
The vehicle (except Crew Cab model) is equipped with a passen-
ger 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 in a frontal collision. When the switch is
turned to the OFF position, the passenger air bag is disabled and
will not inflate in a frontal collision. A passenger air bag OFF indi-
cator 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.
Information necessary to service the system safely is included in
the RS section of this Service Manual.
WARNING:
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