Engine control NISSAN FRONTIER 2003 D22 / 1.G Service Manual

WARNING
cAutomatic transmission models cannot
be push-started or tow-started. This
may cause transmission or other ve-
hicle damage.
cThree-way catalyst equipped models
should not be started by pushing. The
three-way catalyst may be damaged.
cNever try to start the vehicle by towing
it. When the engine starts, the forward
surge could cause the vehicle to collide
with the tow vehicle.If your vehicle is overheating (indicated by an
extremely high temperature gauge reading) , or if
you feel a lack of engine power, detect abnormal
noise, etc. take the following steps.
WARNING
cDo not continue to drive if your vehicle
overheats. Doing so could cause a ve-
hicle fire.
cTo avoid the danger of being scalded,
never remove the radiator cap while the
engine is still hot. When the radiator
cap is removed, pressurized hot water
will spurt out, possibly causing serious
injury.
cDo not open the hood if steam is com-
ing out.
1. Move the vehicle safely off the road, apply
the parking brake and move the shift lever to
N (Neutral) (manual transmission) or to P
(Park) (automatic transmission) .
Do not stop the engine.
2. Turn off the air conditioner (if so equipped) .
Open all the windows, move the heater or air
conditioner temperature control to maximum
hot and fan control to high speed.3. If engine overheating is caused by climbing a
long hill on a hot day, run the engine at a fast
idle (approximately 1,500 r/min) until the
temperature gauge indicator returns to nor-
mal.
4. Get out of the vehicle. Look and listen for
steam or coolant escaping from the radiator
before opening the hood. Wait until no
steam or coolant can be seen before pro-
ceeding.
5. Open the engine hood.
WARNING
If steam or water is coming from the en-
gine, stand clear to prevent getting
burned.
6. Visually check drive belts for damage or
looseness. Also check if the cooling fan is
running. The radiator hoses and radiator
should not leak water. If coolant is leaking,
the water pump belt is missing or loose, or
the cooling fan does not run, stop the en-
gine.
PUSH STARTING IF YOUR VEHICLE OVERHEATS
In case of emergency6-11
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Brake pedal and booster*Check the pedal for
smooth operation and make sure it has the proper
distance under it when depressed fully. Check
the brake booster function. Be certain to keep the
floor mat away from the pedal.
Parking brake*Check that the pedal has the
proper travel and confirm that your vehicle is held
securely on a fairly steep hill with only the parking
brake applied.
Automatic transmission P (Park) position
mechanismCheck that the lock release button
on the shift selector lever operates properly and
smoothly. On a fairly steep hill check that your
vehicle is held securely with the selector lever in
the P position without applying any brakes.
Under the hood and vehicle
The maintenance items listed here should be
checked periodically (for example, each time you
check the engine oil or refuel) .
Windshield washer fluid*Check that there is
adequate fluid in the reservoir.
Engine oil level*Check the level after parking
the vehicle on a level surface with the engine off.
Wait more than 10 minutes for the oil to drain
back into the oil pan.Brake and clutch fluid levels*Make sure that
the brake and clutch fluid level is between the
MIN and MAX lines on the reservoir.
Power steering fluid level* and linesCheck
the level when the fluid is cold, with the engine
off. Check the lines for proper attachment, leaks,
cracks, etc.
Automatic transmission fluid level*Check
the level after putting the selector lever in P with
the engine idling at operating temperature.
Engine coolant level*Check the coolant level
when the engine is cold.
Radiator and hosesCheck the front of the
radiator and clean off any dirt, insects, leaves,
etc., that may have accumulated. Make sure the
hoses have no cracks, deformation, rot or loose
connections.
Engine drive belts*Make sure the drive belts
are not frayed, worn, cracked or oily.
Battery*Check the fluid level in each cell. It
should be between the MAX and MIN lines. Ve-
hicles operated in high temperatures or under
severe conditions require frequent checks of the
battery fluid level.
Exhaust systemMake sure there are no loose
supports, cracks or holes. If the sound of the
exhaust seems unusual or there is a smell ofexhaust fumes, immediately have the exhaust
system inspected by a NISSAN dealer. See the
carbon monoxide warning in the “Starting and
driving” section of this manual.
UnderbodyThe underbody is frequently ex-
posed to corrosive substances such as those
used on icy roads or to control dust. It is very
important to remove these substances from the
underbody, otherwise rust may form on the floor
pan, frame, fuel lines and exhaust system. At the
end of winter, the underbody should be thor-
oughly flushed with plain water, in those areas
where mud and dirt may have accumulated. See
the “Appearance and care” section of this
manual.
Fluid leaksCheck under the vehicle for fuel, oil,
water or other fluid leaks after the vehicle has
been parked for a while. Water dripping from the
air conditioner after use is normal. If you should
notice any leaks or if gasoline fumes are evident,
check for the cause and have it corrected imme-
diately.
8-4Maintenance and do-it-yourself
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9 Technical and consumer information
Capacities and recommended fuel/lubricants.........9-2
Fuel recommendation...........................9-3
Engine oil and oil filter recommendation...........9-5
Recommended SAE viscosity number............9-6
Air conditioner system refrigerant and
lubricant recommendations......................9-6
Specifications.....................................9-7
Engine........................................9-7
Wheels and tires...............................9-8
Dimensions and weights........................9-9
When traveling or registering your vehicle in
another country..................................9-10
Vehicle identification..............................9-10
Vehicle identification number (VIN) plate.........9-10
Vehicle identification number (chassis
number)......................................9-10
Engine serial number...........................9-11
F.M.V.S.S. certification label....................9-11
Emission control information label...............9-12
Tire placard...................................9-12
Air conditioner specification label................9-12
Installing front license plate........................9-13
Vehicle loading information........................9-13Terms........................................9-13
Determining vehicle load capacity...............9-14
Securing the load..............................9-14
Loading tips..................................9-14
Truck-camper loading information..................9-15
Crew Cab Models.............................9-15
King Cab models..............................9-15
Special Body vehicles..........................9-15
Location for center of gravity....................9-15
Payload weight capacity........................9-16
Measurement of weights.......................9-18
Towing a trailer...................................9-18
Maximum load limits...........................9-18
Towing load/specification chart.................9-20
Towing safety.................................9-21
Uniform tire quality grading........................9-23
Emission control system warranty..................9-24
Reporting safety defects (US only).................9-24
Readiness for inspection/maintenance (I/M) test.....9-24
Dynamometer testing for Inspection/
Maintenance (I/M) test (US only)................9-25
Owner’s manual/service manual order information....9-26
In the event of a collision.......................9-27
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ENGINE
Model KA24DE VG33E/VG33ER
Type Gasoline, 4-cycle Gasoline, 4-cycle
Cylinder arrangement 4-cylinder in-line 6-cylinder, V-slanted at 60°
Bore x Stroke in (mm) 3.504 x 3.780 (89. x 96.0) 3.602 x 3.268 (91.5 x 83.0)
Displacement cu in (cm
3) 145.78 (2,389) 199.84 (3,275)
Firing order 1–3–4–2 1–2–3–4–5–6
Idle speed rpm
See the “Emission Control label” on the underside of the hood.
Ignition timing degree (B.T.D.C.) at idle speed degree/rpm
CO percentage at idle speed [No air] %
Except Supercharger Supercharger
Spark plug PFR5G-11 (Standard)*1 PFR5G-11 (Standard)*1 PFR6G-11 (Standard)*1
PFR6G-11 (Cold)*1 PFR6G-11 (Cold)*1 PFR7G-11 (Cold)*1
PFR4G-11 (Hot) *1 PFR5G-11 (Hot) *1
Spark plug gap (Nominal) in (mm) 0.043 (1.1) 0.043 (1.1)
Camshaft operation Timing chain Timing belt*2
Generator belt size
Width x Length in (mm) 0.413 x 35.63 (10.5 x 905) 0.701 x 31.69 (17.8 x 805)
*1: Always check with the Parts Department at a NISSAN dealer for the latest parts information.
*2: Periodic maintenance is necessary. See “Periodic maintenace schedules” in the “NISSAN Service and Maintenace Guide.”
The spark ignition system of this vehicle meets all requirements of the Canadian Interference-Causing Equipment Regulations.
SPECIFICATIONS
Technical and consumer information9-7
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When planning to drive your NISSAN ve-
hicle in another country,you should first find
out if the fuel available is suitable for your vehi-
cle’s engine.
Using fuel with an octane rating that is too low
may cause engine damage. All gasoline vehicles
must be operated with unleaded gasoline. There-
fore, avoid taking your vehicle to areas where
appropriate fuel is not available.
When transferring the registration of your
vehicle to another country, state, province
or district,it may be necessary to modify the
vehicle to meet local laws and regulations.
The laws and regulations for motor vehicle emis-
sion control and safety standards vary according
to the country, state, province or district; there-
fore, vehicle specifications may differ.
When any vehicle is to be taken into an-
other country, state, province or district
and registered, its modifications, transpor-
tation, and registration are the responsibil-
ity of the user. NISSAN is not responsible
for any inconvenience that may result.
VEHICLE IDENTIFICATION NUMBER
(VIN) PLATE
The vehicle identification number (VIN) plate is
attached as shown. This number is the identifica-
tion for your vehicle and is used in the vehicle
registration.
VEHICLE IDENTIFICATION NUMBER
(chassis number)
The vehicle identification number is located as
shown.
WTI0054WTI0065
WHEN TRAVELING OR REGISTERING
YOUR VEHICLE IN ANOTHER
COUNTRYVEHICLE IDENTIFICATION
9-10Technical and consumer information
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Trailer towing tips
In order to gain skill and an understanding of the
vehicle’s behavior, you should practice turning,
stopping and backing up in an area which is free
from traffic. Steering stability and braking perfor-
mance will be somewhat different than under
normal driving conditions.
cAlways secure items in the trailer to prevent
load shift while driving.
cAvoid abrupt starts, acceleration or stops.
cAvoid sharp turns or lane changes.
cAlways drive your vehicle at a moderate speed.
cAlways block the wheels on both vehicle and
trailer when parking. Parking on a slope is not
recommended; however, if you must do so,
and if your vehicle is equipped with an auto-
matic transmission, first block the wheels and
apply the parking brake, and then move the
transmission shift selector lever into the P
(Park) position. If you move the shift selector
lever to the P (Park) position before blocking
the wheels and applying the parking brake,
transmission damage could occur.
cWhen going down a hill, shift into a lower gear
and use the engine braking effect. When go-
ing up a long grade, downshift the transmis-
sion to a lower gear and reduce speed toreduce chances of engine overloading and/or
overheating. However, for long steep grades,
do not stay in 1st or 2nd gear when driving
above 35 MPH (56 km/h) .
cIf the engine coolant rises to an extremely high
temperature when the air conditioner system
is on, turn off the air conditioner. Coolant heat
can be additionally vented by opening the win-
dows, switching the fan control to high and
setting the temperature control to the HOT
position.
cTrailer towing requires more fuel than normal
circumstances.
cAvoid towing a trailer for your vehicle’s first
500 miles (805 km) .
cHave your vehicle serviced more often than at
intervals specified in the recommended Main-
tenance Schedule in the “NISSAN Service
and Maintenance Guide”.
cWhen making a turn, your trailer wheels will be
closer to the inside of the turn than your vehicle
wheels. To compensate for this, make a larger
than normal turning radius during the turn.
cCrosswinds and rough roads will adversely
affect vehicle/trailer handling, possibly caus-
ing vehicle sway. When being passed by
larger vehicles, be prepared for possible
changes in crosswinds that could affect ve-hicle handling. If swaying does occur, firmly
grip the steering wheel, steer straight ahead,
and immediately (but gradually) reduce vehicle
speed. This combination will help stabilize the
vehicle. Never increase speed.
cBe careful when passing other vehicles. Pass-
ing while towing a trailer requires considerably
more distance than normal passing. Remem-
ber, the length of the trailer must also pass the
other vehicle before you can safely change
lanes.
cTo maintain engine braking efficiency and
electrical charging performance, do not use
5th gear (manual transmission) or overdrive
(automatic transmission) .
cAvoid holding the brake pedal down too long
or too frequently. This could cause the brakes
to overheat, resulting in reduced braking effi-
ciency.
When towing a trailer, transmission
oil/fluid should be changed more fre-
quently. For additional information, see the
“Maintenance and do-it-yourself” section
earlier in this manual.
9-22Technical and consumer information
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Your NISSAN vehicle is covered by the following
emission warranties:
For US
1. Emission Defects Warranty
2. Emissions Performance Warranty
Details of these warranties may be found with
other vehicle warranties in your Warranty Infor-
mation Booklet which comes with your NISSAN
vehicle. If you did not receive a Warranty Informa-
tion Booklet, or it is lost, you may obtain a re-
placement by writing to:
cNissan North America, Inc.
Consumer Affairs Department
P.O. Box 191
Gardena, CA 90248-0191
For Canada
Emission Control System Warranty
Details of these warranties may be found with
other vehicle warranties in your Warranty Infor-
mation Booklet which comes with your NISSAN
vehicle. If you did not receive a Warranty Informa-
tion Booklet, or it is lost, you may obtain a re-
placement by writing to:
cNissan Canada Inc.
5290 Orbitor Drive
Mississauga, Ontario, L4W 4Z5If you believe that your vehicle has a defect which
could cause a crash or could cause injury or
death, you should immediately inform the Na-
tional Highway Traffic Safety Administration
(NHTSA) in addition to notifying NISSAN.
If NHTSA receives similar complaints, it may
open an investigation, and if it finds that a safety
defect exists in a group of vehicles, it may order a
recall and remedy campaign. However, NHTSA
cannot become involved in individual problems
between you, your dealer, or NISSAN.
To contact NHTSA, you may call the Auto Safety
Hotline toll-free at 1-888-327-4236. You may
also write to: NHTSA, U.S. Department of Trans-
portation, Washington, D.C. 20590. You can also
obtain other information about motor vehicle
safety from the Hotline.
You may notify NISSAN by contacting our Con-
sumer Affairs Department, toll-free, at 1-800-
NISSAN-1.
In Hawaii call 1-808-836-0888.Due to legal requirements in some states and
Canadian Provinces, your vehicle may be re-
quired to be in what is called the “ready condi-
tion” for an Inspection/Maintenance (I/M) test of
the emission control system.
The vehicle is set to the “ready condition”’ when it
is driven through certain driving patterns. Usually,
the ready condition can be obtained by ordinary
usage of the vehicle.
If a powertrain system component is repaired or
the battery is disconnected, the vehicle may be
reset to a “not ready” condition. Before taking the
I/M test, drive the vehicle through the following
pattern to set the vehicle to the ready condition. If
you cannot or do not want to perform the driving
pattern, a NISSAN dealer can conduct it for you.
WARNING
Always drive the vehicle in a safe and
prudent manner according to traffic con-
ditions and obey all traffic laws.
1. Start the engine when the engine coolant
temperature gauge needle points to C. Al-
low the engine to idle until the gauge needle
points between the C and H (normal oper-
ating temperature) .
EMISSION CONTROL SYSTEM
WARRANTYREPORTING SAFETY DEFECTS (US
only)READINESS FOR INSPECTION/
MAINTENANCE (I/M) TEST
9-24Technical and consumer information
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2. Accelerate the vehicle to 55 mph (88 km/h) ,
then quickly release the accelerator pedal
completely and keep it released for at least 6
seconds.
3. Quickly depress the accelerator pedal for a
moment, then drive the vehicle at a speed of
53 - 60 mph (85 - 97 km/h) for at least 5
minutes.
4. Stop the vehicle.
5. Accelerate the vehicle to 35 mph (55 km/h)
and maintain the speed for 20 seconds.
6. Repeat steps 4 through 5 at least three
times.
7. Accelerate the vehicle to 55 mph (88 km/h)
and maintain the speed for at least 3 min-
utes.
8. Stop the vehicle and turn the engine off.
9. Repeat steps 1 through 8 at least one more
time.
If steps 1 through 7 are interrupted, repeat the
preceding step. Any safe driving mode is accept-
able between steps. Do not stop the engine until
step 7 is completed. If you cannot or do not want
to perform the driving pattern, a NISSAN dealer
can conduct it for you.DYNAMOMETER TESTING FOR
INSPECTION/MAINTENANCE (I/M)
TEST (US only)
Due to legal requirements in some states/areas,
your vehicle may be tested for emissions on a
dynamometer. The transfer control lever (if so
equipped) MUST be in the 2H position for I/M
testing on a two wheel dynamometer.
WARNING
cIf the transfer control lever is not in the
2H position during the dynamometer
I/M testing, the vehicle could come off
the dynamometer and cause serious
personal injury and/or body damage to
the vehicle.
cSerious damage will occur to the 4WD
system if the transfer control lever is
not in the 2H position.
Technical and consumer information9-25
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10 Index
A
Air bag
Passenger supplemental air bag
ON/OFF switch and light..........1-15
Air bag (See supplemental restraint
system)......................1-6
Air bag warning light...........1-17, 2-12
Air cleaner housing filter............8-23
Air conditioner
Air conditioner operation...........4-5
Air conditioner service............4-9
Air conditioner specification label.....9-12
Air conditioner system refrigerant and
lubrication recommendations........9-6
Heater and air conditioner controls.....4-2
Servicing air conditioner...........4-9
Air flow charts..................4-6
Alarm system
(See vehicle security system).........2-15
Anchor point locations.............1-40
Antenna.....................4-28
Anti-lock brake system (ABS).........5-27
Anti-lock brake warning light..........2-10
Audible reminders................2-15
Audio system..................4-10
Compact disc (CD) player.........4-15
FM-AM radio with compact disc (CD)
changer...................4-16
FM-AM radio with compact disc (CD)
player....................4-12Radio....................4-10
Steering wheel audio control switch. . . .4-28
Auto-lock free-running hubs..........5-22
Automatic
Automatic power window switch.....2-29
Automatic transmission fluid (ATF). . . .8-14
Driving with automatic transmission. . . .5-10
Transmission selector lever lock
release....................5-14
B
Battery......................8-18
Charge warning light............2-11
Battery replacement
(See remote keyless entry system).......3-7
Before starting the engine............5-9
Belts (See drive belts).............8-20
Brake
Anti-lock brake system (ABS).......5-27
Brake booster................8-28
Brake fluid..................8-16
Brake light (See stop light).........8-34
Brake pedal.................8-27
Brake system................5-26
Brake warning light.............2-10
Brake wear indicators........2-15, 8-28
Parking brake check............8-27
Parking brake operation..........5-18
Self-adjusting brakes............8-28
Break-in schedule................5-20Bulb check/instrument panel..........2-9
Bulb replacement................8-34
C
Capacities and recommended
fuel/lubricants...................9-2
Car phone or CB radio.............4-29
Cargo lamp switch...............2-23
Cargo (See vehicle loading information) . . .9-13
CD player (See audio system).........4-15
Check engine indicator light
(See malfunction indicator light)........2-13
Child restraint with top tether
strap.......................1-40
Child restraints..........1-22, 1-29, 1-38
Precautions on child restraints.......1-29
Child safety rear door lock............3-4
Chimes, audible reminders...........2-15
Cleaning exterior and interior..........7-2
Clock...................4-13, 4-18
Clutch
Clutch fluid.................8-17
Cold weather driving..............5-30
Compact disc (CD) player...........4-15
Controls
Audio controls (steering wheel)......4-28
Heater and air conditioner controls.....4-2
Coolant
Capacities and recommended
fuel/lubricants.................9-2
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Changing engine coolant..........8-10
Checking engine coolant level........8-9
Engine coolant temperature gauge.....2-5
Corrosion protection...............7-5
Cruise control..................5-19
Cup holders...................2-25
D
Daytime running light system
(Canada only)..................2-21
Defogger switch
Rear window defogger switch.......2-19
Dimensions and weights.............9-9
Door locks....................3-2
Door open warning light............2-11
Drive belts....................8-20
Driving
Auto-lock free-running hubs........5-22
Cold weather driving............5-30
Driving with automatic transmission. . . .5-10
Driving with manual transmission.....5-16
Precautions when starting and driving . . .5-2
E
Economy - fuel.................5-21
Emission control information label.......9-12
Emission control system warranty.......9-24
Engine
Before starting the engine..........5-9
Capacities and recommended
fuel/lubricants.................9-2
Changing engine coolant..........8-10Changing engine oil............8-11
Changing engine oil filter..........8-13
Checking engine coolant level........8-9
Checking engine oil level..........8-10
Engine compartment check locations. . . .8-9
Engine coolant temperature gauge.....2-5
Engine cooling system............8-9
Engine oil..................8-10
Engine oil and oil filter
recommendation...............9-5
Engine oil pressure warning light.....2-11
Engine oil viscosity..............9-5
Engine serial number............9-11
Engine specifications.............9-7
Starting the engine..............5-9
Exhaust gas (Carbon monoxide)........5-2
F
First aid kit....................6-2
Flashers
(See hazard warning flasher switch)......2-22
Flat tire......................6-2
Floor mat positioning aid.............7-4
Fluid
Automatic transmission fluid (ATF). . . .8-14
Brake fluid..................8-16
Capacities and recommended
fuel/lubricants.................9-2
Clutch fluid.................8-17
Engine coolant................8-9
Engine oil..................8-10
Power steering fluid.............8-15
Window washer fluid............8-17
F.M.V.S.S. certification label..........9-11Front fog light switch..............2-22
Front seats....................1-2
Fuel
Capacities and recommended
fuel/lubricants.................9-2
Fuel economy................5-21
Fuel filler cap................3-11
Fuel gauge..................2-6
Fuel octane rating..............9-4
Fuel recommendation............9-3
Fuses......................8-29
G
Gauge
Engine coolant temperature gauge.....2-5
Fuel gauge..................2-6
Odometer...................2-3
Speedometer.................2-3
Tachometer..................2-5
General maintenance..............8-2
Glove box....................2-26
Glove box lock.................2-26
H
Hazard warning flasher switch.........2-22
Head restraints..................1-5
Headlight aiming adjustment..........8-32
Headlight and turn signal switch........2-20
Headlights....................8-31
Heater
Heater and air conditioner controls.....4-2
Heater operation...............4-4
10-2
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