Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 2006-2009 Approved Nissan Frontier 2007 EM
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B ENGINE
A
SECTION
ENGINE MECHANICAL
EM EM
C
D
E
CONTENTS
QR INSTALLATION .................................................. 16 . F
Changing Air Cleaner Filter ................................... 17 .
PRECAUTIONS ......................................................... 5 . REMOVAL .......................................................... 17 .
Precautions for Supplemental Restraint System INSTALLATION .................................................. 17 . G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- INTAKE MANIFOLD ................................................ 18 .
SIONER" ................................................................. 5. Removal and Installation ....................................... 18 .
Precautions for Drain Engine Coolant and Engine REMOVAL .......................................................... 18 .
Oil ............................................................................ 5
. H
INSTALLATION .................................................. 19 .
Precautions for Disconnecting Fuel Piping ............. 5 . INSPECTION AFTER INSTALLATION ............... 20 .
Precautions for Removal and Disassembly ............ 5 . EXHAUST MANIFOLD AND THREE WAY CATA-
Precautions for Inspection, Repair and Replace- LYST ......................................................................... 21
. I
ment ........................................................................ 5
. Removal and Installation ....................................... 21 .
Precautions for Assembly and Installation .............. 5 . REMOVAL .......................................................... 21 .
Parts Requiring Angle Tightening ............................ 6 . INSPECTION AFTER REMOVAL ...................... 22 . J
Precautions for Liquid Gasket ................................. 6 . INSTALLATION .................................................. 22 .
REMOVAL OF LIQUID GASKET SEALING ......... 6 . OIL PAN ................................................................... 23
.
LIQUID GASKET APPLICATION PROCEDURE 6 ..... Removal and Installation ....................................... 23 .
PREPARATION .......................................................... 8 . K
REMOVAL .......................................................... 23 .
Special Service Tools .............................................. 8 . INSTALLATION .................................................. 24 .
Commercial Service Tools ..................................... 10 . INSPECTION AFTER INSTALLATION ............... 24 .
NOISE, VIBRATION AND HARSHNESS (NVH) IGNITION COIL ........................................................ 26 . L
TROUBLESHOOTING ............................................. 12 . Removal and Installation ....................................... 26 .
NVH Troubleshooting -- Engine Noise ................. 12 . REMOVAL .......................................................... 26 .
Use the Chart Below to Help You Find the Cause INSTALLATION .................................................. 26 . M
of the Symptom. .................................................... 13 . SPARK PLUG .......................................................... 27 .
DRIVE BELTS .......................................................... 14 . Changing Spark Plugs ........................................... 27 .
Checking Drive Belt ............................................... 14 . REMOVAL .......................................................... 27 .
Tension Adjustment ............................................... 14 . INSPECTION AFTER REMOVAL ...................... 27 .
Removal and Installation ....................................... 14 . INSTALLATION .................................................. 28 .
REMOVAL .......................................................... 14 . FUEL INJECTOR AND FUEL TUBE ....................... 29 .
INSTALLATION .................................................. 15 . Removal and Installation ....................................... 29 .
Removal and Installation of Drive Belt Auto-Ten- REMOVAL .......................................................... 29 .
sioner .................................................................... 15
. INSTALLATION .................................................. 31 .
REMOVAL .......................................................... 15 . INSPECTION AFTER INSTALLATION ............... 33 .
INSTALLATION .................................................. 15 . ROCKER COVER .................................................... 34 .
AIR CLEANER AND AIR DUCT .............................. 16 . Removal and Installation ....................................... 34 .
Removal and Installation ....................................... 16 . REMOVAL .......................................................... 34 .
REMOVAL .......................................................... 16 . INSTALLATION .................................................. 35 .
INSPECTION AFTER REMOVAL ...................... 16 . CAMSHAFT ............................................................. 36 .
Removal and Installation ....................................... 36 .
Revision: September 2006 EM-1 2007 Frontier
REMOVAL .......................................................... 36 . HOW TO SELECT MAIN BEARING ...................88 .
INSPECTION AFTER REMOVAL ....................... 38 . Inspection After Disassembly .................................92 .
INSTALLATION ................................................... 41 . CRANKSHAFT END PLAY .................................92 .
INSPECTION AFTER INSTALLATION ............... 44 . CONNECTING ROD SIDE CLEARANCE ..........92 .
Valve Clearance ..................................................... 45. PISTON TO PISTON PIN OIL CLEARANCE ......92 .
INSPECTION ...................................................... 45 . PISTON RING SIDE CLEARANCE ....................93 .
ADJUSTMENT ................................................... 46 . PISTON RING END GAP ...................................93 .
TIMING CHAIN ......................................................... 48 . CONNECTING ROD BEND AND TORSION ......94 .
Removal and Installation ....................................... 48 . CONNECTING ROD BIG END DIAMETER .......94 .
REMOVAL .......................................................... 49 . CONNECTING ROD BUSHING OIL CLEAR-
INSPECTION AFTER REMOVAL ....................... 52 . ANCE ..................................................................94
.
INSTALLATION ................................................... 52 . CYLINDER BLOCK DISTORTION .....................95 .
INSPECTION AFTER INSTALLATION ............... 56 . MAIN BEARING HOUSING INNER DIAMETER...96
OIL SEAL ................................................................. 57
. PISTON TO CYLINDER BORE CLEARANCE ...96
Removal and Installation of Valve Oil Seal ............ 57 . CRANKSHAFT MAIN JOURNAL DIAMETER ....97 .
REMOVAL .......................................................... 57 . CRANKSHAFT PIN JOURNAL DIAMETER .......98 .
INSTALLATION ................................................... 57 . OUT-OF-ROUND AND TAPER OF CRANK-
Removal and Installation of Front Oil Seal ............ 57 . SHAFT ................................................................98
.
REMOVAL .......................................................... 57 . CRANKSHAFT RUNOUT ...................................98 .
INSTALLATION ................................................... 58 . CONNECTING ROD BEARING OIL CLEAR-
Removal and Installation of Rear Oil Seal ............. 58 . ANCE ..................................................................98
.
REMOVAL .......................................................... 58 . MAIN BEARING OIL CLEARANCE ....................99 .
INSTALLATION ................................................... 58 . MAIN BEARING CRUSH HEIGHT ................... 100 .
CYLINDER HEAD .................................................... 60 . CONNECTING ROD BEARING CRUSH
On-Vehicle Service ................................................ 60 . HEIGHT ............................................................ 100
.
CHECKING COMPRESSION PRESSURE ........ 60 . LOWER CYLINDER BLOCK MOUNTING BOLT
Removal and Installation ....................................... 61 . OUTER DIAMETER .......................................... 100 .
REMOVAL .......................................................... 61 . CONNECTING ROD BOLT OUTER DIAMETER.100
INSPECTION AFTER REMOVAL ....................... 62 . MOVEMENT AMOUNT OF FLYWHEEL (M/T
INSTALLATION ................................................... 63 . MODELS) .......................................................... 100
.
INSPECTION AFTER INSTALLATION ............... 63 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 102 .
Disassembly and Assembly ................................... 64 . Standard and Limit ............................................... 102.
DISASSEMBLY .................................................. 64 . GENERAL SPECIFICATIONS .......................... 102 .
ASSEMBLY ........................................................ 65 . DRIVE BELT ..................................................... 102.
Inspection After Disassembly ................................ 67 . EXHAUST MANIFOLD AND THREE WAY CAT-
VALVE DIMENSIONS ......................................... 67 . ALYST ASSEMBLY ........................................... 102 .
VALVE GUIDE CLEARANCE ............................. 67 . SPARK PLUG ................................................... 102 .
VALVE GUIDE REPLACEMENT ........................ 67 . CYLINDER HEAD ............................................. 102 .
VALVE SEAT CONTACT .................................... 69 . VALVE ............................................................... 103
.
VALVE SEAT REPLACEMENT .......................... 69 . CAMSHAFT AND CAMSHAFT BEARING ........ 107 .
VALVE SPRING SQUARENESS ........................ 70 . CYLINDER BLOCK ........................................... 107 .
VALVE SPRING DIMENSIONS AND VALVE PISTON, PISTON RING AND PISTON PIN ..... 109 .
SPRING PRESSURE LOAD .............................. 70 . CONNECTING ROD ......................................... 110 .
ENGINE ASSEMBLY ............................................... 71 . CRANKSHAFT .................................................. 110 .
Removal and Installation ....................................... 71 . MAIN BEARING ................................................ 112 .
REMOVAL .......................................................... 72 . CONNECTING ROD BEARING ........................ 113 .
INSTALLATION ................................................... 73 .
INSPECTION AFTER INSTALLATION ............... 73 . VQ
CYLINDER BLOCK .................................................. 75 .
Disassembly and Assembly ................................... 75 . PRECAUTIONS ...................................................... 114 .
DISASSEMBLY .................................................. 76 . Precautions for Supplemental Restraint System
ASSEMBLY ........................................................ 80 . (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
How to Select Piston and Bearing ......................... 85 . SIONER" .............................................................. 114
.
DESCRIPTION ................................................... 85 . Precautions for Drain Engine Coolant .................. 114 .
HOW TO SELECT PISTON ................................ 85 . Precautions for Disconnecting Fuel Piping .......... 114 .
HOW TO SELECT CONNECTING ROD BEAR- Precautions for Removal and Disassembly ......... 114 .
ING ..................................................................... 86
. Precautions for Inspection, Repair and Replace-
ment ..................................................................... 114
.
Precautions for Assembly and Installation ........... 114 .
Revision: September 2006 EM-2 2007 Frontier
Parts Requiring Angle Tightening .........................115 . OIL PAN AND OIL STRAINER .............................. 137 .
Precautions for Liquid Gasket ..............................115 . Removal and Installation ..................................... 137 . A
REMOVAL OF LIQUID GASKET SEALING ......115 . REMOVAL (LOWER) ........................................ 137 .
LIQUID GASKET APPLICATION PROCEDURE ..115 INSPECTION AFTER REMOVAL .................... 138 .
PREPARATION .......................................................117 . INSTALLATION (LOWER) ................................ 138 . EM
Special Service Tools ...........................................117 . INSPECTION AFTER INSTALLATION ............. 139 .
Commercial Service Tools ....................................119 . REMOVAL (UPPER) ........................................ 139 .
NOISE, VIBRATION AND HARSHNESS (NVH) INSPECTION AFTER REMOVAL .................... 140 .
TROUBLESHOOTING ........................................... 121 . INSTALLATION (UPPER) ................................. 140 . C
NVH Troubleshooting --Engine Noise ................ 121 . INSPECTION AFTER INSTALLATION ............. 141 .
Use the Chart Below to Help You Find the Cause IGNITION COIL ...................................................... 142
.
of the Symptom ................................................... 122 . Removal and Installation ..................................... 142 . D
ENGINE ROOM COVER ....................................... 123 . REMOVAL (LEFT BANK) ................................. 142 .
Removal and Installation ..................................... 123 . INSTALLATION (LEFT BANK) ......................... 142 .
REMOVAL ........................................................ 123 . REMOVAL (RIGHT BANK) ............................... 142 . E
INSTALLATION ................................................ 123 . INSTALLATION (RIGHT BANK) ....................... 142 .
DRIVE BELTS ........................................................ 124 . SPARK PLUG ........................................................ 143.
Checking Drive Belts ........................................... 124 . Changing Spark Plugs ......................................... 143 .
Tension Adjustment ............................................. 124 . REMOVAL ........................................................ 143. F
Removal and Installation ..................................... 124 . INSPECTION AFTER REMOVAL .................... 143 .
DRIVE BELT .................................................... 124 . INSTALLATION ................................................ 144 .
INSTALLATION ................................................ 125 . FUEL INJECTOR AND FUEL TUBE ..................... 145 . G
Drive Belt Auto-Tensioner and Idler Pulley .......... 125 . Removal and Installation ..................................... 145 .
REMOVAL ........................................................ 125 . REMOVAL ........................................................ 145.
INSTALLATION ................................................ 125 . INSTALLATION ................................................ 148 . H
AIR CLEANER AND AIR DUCT ............................ 126 . INSPECTION AFTER INSTALLATION ............. 150 .
Removal and Installation ..................................... 126 . ROCKER COVER .................................................. 151 .
REMOVAL ........................................................ 126 . Removal and Installation ..................................... 151 .
I
INSPECTION AFTER REMOVAL .................... 126 . REMOVAL (LEFT BANK) ................................. 151 .
INSTALLATION ................................................ 126 . INSTALLATION (LEFT BANK) ......................... 152 .
Changing Air Cleaner Filter ................................. 126 . REMOVAL (RIGHT BANK) ............................... 153 .
REMOVAL ........................................................ 126 . INSTALLATION (RIGHT BANK) ....................... 154 . J
INSTALLATION ................................................ 126 . FRONT TIMING CHAIN CASE .............................. 156 .
INTAKE MANIFOLD COLLECTOR ....................... 127 . Removal and Installation ..................................... 156 .
Removal and Installation ..................................... 127 . REMOVAL ........................................................ 156. K
REMOVAL ........................................................ 128 . INSTALLATION ................................................ 160 .
INSTALLATION ................................................ 129 . INSPECTION AFTER INSTALLATION ............. 163 .
INTAKE MANIFOLD .............................................. 130 . TIMING CHAIN ....................................................... 165
.
L
Removal and Installation ..................................... 130 . Removal and Installation ..................................... 165 .
REMOVAL ........................................................ 130 . REMOVAL ........................................................ 166.
INSPECTION AFTER REMOVAL .................... 130 . INSPECTION AFTER REMOVAL .................... 173 .
INSTALLATION ................................................ 131 . INSTALLATION ................................................ 174 . M
EXHAUST MANIFOLD AND THREE WAY CATA- INSPECTION AFTER INSTALLATION ............. 184 .
LYST ...................................................................... 132
. CAMSHAFT ........................................................... 185
.
Removal and Installation ..................................... 132 . Removal and Installation ..................................... 185 .
REMOVAL (LEFT BANK) ................................. 132 . REMOVAL ........................................................ 186.
INSPECTION AFTER REMOVAL .................... 133 . INSPECTION AFTER REMOVAL .................... 187 .
INSTALLATION (LEFT BANK) ......................... 134 . INSTALLATION ................................................ 190 .
REMOVAL (RIGHT BANK) .............................. 135 . INSPECTION AFTER INSTALLATION ............. 193 .
INSPECTION AFTER REMOVAL .................... 135 . Valve Clearance .................................................. 194
.
INSTALLATION (RIGHT BANK) ....................... 136 . INSPECTION ................................................... 194 .
ADJUSTMENT ................................................. 197 .
OIL SEAL ............................................................... 199
.
Removal and Installation of Valve Oil Seal .......... 199 .
REMOVAL ........................................................ 199.
INSTALLATION ................................................ 199 .
Removal and Installation of Front Oil Seal .......... 200 .
REMOVAL ........................................................ 200.
Revision: September 2006 EM-3 2007 Frontier
INSTALLATION ................................................. 200 . ANCE ................................................................ 235
.
Removal and Installation of Rear Oil Seal ........... 200 . CYLINDER BLOCK DISTORTION ................... 236 .
REMOVAL ........................................................ 200 . MAIN BEARING HOUSING INNER DIAMETER.237
INSTALLATION ................................................. 201 . PISTON TO CYLINDER BORE CLEARANCE . 237
CYLINDER HEAD .................................................. 202 . CRANKSHAFT MAIN JOURNAL DIAMETER .. 238 .
On-Vehicle Service .............................................. 202 . CRANKSHAFT PIN JOURNAL DIAMETER ..... 239 .
CHECKING COMPRESSION PRESSURE ...... 202 . CRANKSHAFT OUT-OF-ROUND AND TAPER.239
Removal and Installation ..................................... 203 . CRANKSHAFT RUNOUT ................................. 239 .
REMOVAL ........................................................ 203 . CONNECTING ROD BEARING OIL CLEAR-
INSPECTION AFTER REMOVAL ..................... 204 . ANCE ................................................................ 239
.
INSTALLATION ................................................. 205 . MAIN BEARING OIL CLEARANCE .................. 240 .
INSPECTION AFTER INSTALLATION ............. 206 . CRUSH HEIGHT OF MAIN BEARING ............. 241 .
Disassembly and Assembly ................................. 207 . CRUSH HEIGHT OF CONNECTING ROD
DISASSEMBLY ................................................ 207 . BEARING .......................................................... 241
.
ASSEMBLY ...................................................... 208 . LOWER CYLINDER BLOCK BOLT OUTER
Inspection After Disassembly .............................. 209 . DIAMETER ....................................................... 241.
VALVE DIMENSIONS ....................................... 209 . CONNECTING ROD BOLT OUTER DIAMETER.242
VALVE GUIDE CLEARANCE ........................... 209 . FLYWHEEL RUNOUT (M/T) ............................. 242 .
VALVE GUIDE REPLACEMENT ...................... 210 . MOVEMENT AMOUNT OF FLYWHEEL (M/T
VALVE SEAT CONTACT .................................. 211 . MODELS) .......................................................... 242
.
VALVE SEAT REPLACEMENT ........................ 211 . DRIVE PLATE ................................................... 243 .
VALVE SPRING SQUARENESS ...................... 212 . OIL JET ............................................................. 243
.
VALVE SPRING DIMENSIONS AND VALVE OIL JET RELIEF VALVE ................................... 243 .
SPRING PRESSURE LOAD ............................ 213 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 244 .
ENGINE ASSEMBLY ............................................. 214 . Standard and Limit ............................................... 244.
Removal and Installation ..................................... 214 . GENERAL SPECIFICATIONS .......................... 244 .
REMOVAL ........................................................ 215 . DRIVE BELT ..................................................... 245.
INSTALLATION ................................................. 216 . INTAKE MANIFOLD COLLECTOR, INTAKE
INSPECTION AFTER INSTALLATION ............. 216 . MANIFOLD AND EXHAUST MANIFOLD ......... 245 .
CYLINDER BLOCK ................................................ 217 . SPARK PLUG ................................................... 245 .
Disassembly and Assembly ................................. 217 . CAMSHAFT AND CAMSHAFT BEARING ........ 246 .
DISASSEMBLY ................................................ 218 . CYLINDER HEAD ............................................. 248 .
ASSEMBLY ...................................................... 222 . CYLINDER BLOCK ........................................... 251 .
How to Select Piston and Bearing ....................... 228 . PISTON, PISTON RING AND PISTON PIN ..... 252 .
DESCRIPTION ................................................. 228 . CONNECTING ROD ......................................... 253 .
HOW TO SELECT PISTON .............................. 228 . CRANKSHAFT .................................................. 254 .
HOW TO SELECT CONNECTING ROD BEAR- MAIN BEARING ................................................ 255 .
ING ................................................................... 229
. CONNECTING ROD BEARING ........................ 256 .
HOW TO SELECT MAIN BEARING ................. 230 .
Inspection After Disassembly .............................. 233 .
CRANKSHAFT END PLAY ............................... 233 .
CONNECTING ROD SIDE CLEARANCE ........ 233 .
PISTON TO PISTON PIN OIL CLEARANCE ... 233 .
PISTON RING SIDE CLEARANCE .................. 234 .
PISTON RING END GAP ................................. 234 .
CONNECTING ROD BEND AND TORSION .... 235 .
CONNECTING ROD BIG END DIAMETER ..... 235 .
CONNECTING ROD BUSHING OIL CLEAR-
Revision: September 2006 EM-4 2007 Frontier
PRECAUTIONS
[QR]
PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" EBS00T36
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along EM
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual. C
WARNING:
G 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 per-
formed by an authorized NISSAN/INFINITI dealer. D
G Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section. E
G Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors. F
Precautions for Drain Engine Coolant and Engine Oil EBS00NGC
Drain engine coolant and engine oil when the engine is cooled. G
Precautions for Disconnecting Fuel Piping EBS00NGD
G Before starting work, make sure no fire or spark producing items are in the work area.
H
G Release fuel pressure before disassembly.
G After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS00NGE
I
G When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
J
G Exercise maximum care to avoid damage to mating or sliding surfaces.
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. K
G When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be
used where noted in the step.
L
Precautions for Inspection, Repair and Replacement EBS00NGF
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary. M
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
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.
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
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.
G Release air within route when refilling after draining engine coolant.
Revision: September 2006 EM-5 2007 Frontier
PRECAUTIONS
[QR]
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.
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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