belt NISSAN FRONTIER 2003 D22 / 1.G Repair Manual

When performing any inspection or maintenance
work on your vehicle, always take care to prevent
serious accidental injury to yourself or damage to
the vehicle. The following are general precau-
tions which should be closely observed.
WARNING
cPark the vehicle on a level surface, ap-
ply the parking brake securely and
block the wheels to prevent the vehicle
from moving. For manual transmission
models, move the shift lever to N (Neu-
tral) . For automatic transmission mod-
els, move the selector lever to P (Park) .
cBe sure the ignition key is in the OFF or
LOCK position when performing any
parts replacement or repairs.
cNever leave the engine or automatic
transmission related component har-
nesses disconnected while the ignition
switch is in the ON position.
cNever connect or disconnect the battery
or any transistorized component while
the ignition switch is in the ON position.
cIf you must work with the engine run-
ning, keep your hands, clothing, hair
and tools away from moving fans, belts
and any other moving parts.cIt is advisable to secure or remove any
loose clothing and remove any jewelry,
such as rings, watches, etc. before
working on your vehicle.
cAlways wear eye protection whenever
you work on your vehicle.
cIf you must run the engine in an en-
closed space such as a garage, be sure
there is proper ventilation for exhaust
gases to escape.
cNever get under the vehicle while it is
supported only by a jack. If it is neces-
sary to work under the vehicle, support
it with safety stands.
cKeep smoking materials, flame and
sparks away from the fuel tank and
battery.
cOn gasoline engine models with the
multiport fuel injection (MFI) system,
the fuel filter or fuel lines should be
serviced by a NISSAN dealer because
the fuel lines are under high pressure
even when the engine is off.
CAUTION
cDo not work under the hood while the
engine is hot. Turn the engine off and
wait until it cools down.
cAvoid contact with used engine oil and
coolant. Improperly disposed engine
oil, engine coolant and/or other vehicle
fluids can damage the environment. Al-
ways conform to local regulations for
disposal of vehicle fluid.
This “Maintenance and do-it-yourself” section
gives instructions regarding only those items
which are relatively easy for an owner to perform.
A genuine NISSAN service manual is also avail-
able. See “Owner’s Manual/Service Manual or-
der information” in the “Technical and consumer
information” section of this manual.
You should be aware that incomplete or improper
servicing may result in operating difficulties or
excessive emissions, and could affect warranty
coverage.If in doubt about any servicing,
have it done by a NISSAN dealer.
MAINTENANCE PRECAUTIONS
Maintenance and do-it-yourself8-5
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WARNING
cWhen the engine is running, keep
hands, jewelry and clothing away from
any moving parts such as the cooling
fan and drive belts.
cAutomatic transmission fluid is poison-
ous and should be stored carefully in
marked containers out of the reach of
children.
TEMPERATURE CONDITIONS FOR
CHECKING
cThe fluid level should be checked using the
HOT range on the dipstick after the following
conditions have been met:
– The engine should be warmed up to op-
erating temperature.
– The vehicle should be driven at least 5
minutes.
– The automatic transmission fluid should
be warmed to 122 - 176°F (50 - 80°C) .cThe fluid can be checked at fluid temperatures
of 86 - 122°F (30 - 50°C) using the COLD
range on the dipstick after the engine is
warmed up and before driving. However, the
fluid should be re-checked using the HOT
range.
1. Park the vehicle on a level surface and set
the parking brake.
2. Start the engine and then move the shift
selector lever through each gear range, end-
ing in P (Park) .
3. Check the fluid level with the engine idling.
KA24DE engine
WDI0279
VG33E/VG33ER engine
WDI0280
AUTOMATIC TRANSMISSION FLUID
8-14Maintenance and do-it-yourself
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1 Crank pulley
2 Water pump
3 Generator
4 Air conditioner compressor
5 Power steering fluid pump
: Tension checking points
WARNING
Be sure the ignition key is in the OFF or
LOCK position. The engine could rotate
unexpectedly.1. Visually inspect each belt for signs of un-
usual wear, cuts, fraying or looseness. If the
belt is in poor condition or is loose, have it
replaced or adjusted by a NISSAN dealer.
2. Have the belts checked regularly for condi-
tion and tension in accordance with the
maintenance schedule found in the
“NISSAN Service and Maintenance Guide”.
1 Crank pulley
2 Water pump
3 Alternator
4 Air conditioner compressor
5 Power steering fluid pump
: Tension checking points
KA24DE engine
WDI0286
VG33E engine
WDI0287
DRIVE BELTS
8-20Maintenance and do-it-yourself
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cThe original tires have built-in tread
wear indicators. When the wear indica-
tors are visible, the tire(s) should be
replaced.
cImproper service of the spare tire may
result in serious personal injury. If it is
necessary to repair the spare tire, con-
tact a NISSAN dealer.
cFor additional information regarding
tires, refer to Important Tire Safety In-
formation (US) or Tire Safety Informa-
tion (Canada) in the Warranty Informa-
tion Booklet.
Replacing wheels and tires
When replacing a tire, use the same size, tread
design, speed rating and load carrying capacity
as originally equipped. Recommended types and
sizes are shown in “Wheels/tire size” in the
“Technical and consumer information” section of
this manual.
WARNING
cThe use of tires other than those recom-
mended or the mixed use of tires of
different brands, construction (bias,
bias-belted or radial) , or tread patterns
can adversely affect the ride, braking,
handling, ground clearance, body-to-
tire clearance, tire chain clearance,
speedometer calibration, headlight aim
and bumper height. Some of these ef-
fects may lead to accidents and could
result in serious personal injury.
cIf the wheels are changed for any rea-
son, always replace with wheels which
have the same off-set dimension.
Wheels of a different off-set could
cause premature tire wear, degrade ve-
hicle handling characteristics and/or
interference with the brake
discs/drums. Such interference can
lead to decreased braking efficiency
and/or early brake pad/shoe wear. Re-
fer to “Wheel/tire size” in the “Techni-
cal and consumer information” section
of this manual for wheel off-set
dimensions.cWhen a spare tire is mounted or a wheel
is replaced, the low tire pressure warn-
ing system will not function. Contact
your NISSAN dealer as soon as pos-
sible for tire replacement and/or sys-
tem resetting (for models with the low
tire pressure warning system) .
cDo not install a deformed wheel or tire
even if it has been repaired. Such
wheels or tires could have structural
damage and could fail without warning.
cThe use of retread tires is not
recommended.
cFor additional information regarding
tires, refer to Important Tire Safety In-
formation (US) or Tire Safety Informa-
tion (Canada) in the Warranty Informa-
tion Booklet.
8-40Maintenance and do-it-yourself
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Four-wheel drive models
CAUTION
Always use tires of the same type, size,
brand, construction (bias, bias-belted or
radial) , and tread pattern on all four
wheels. Failure to do so may result in a
circumference difference between tires
on the front and rear axles which will
cause excessive tire wear and may dam-
age the transmission, transfer case and
differential gears.
If excessive tire wear is found, it is recommended
that all four tires be replaced with tires of the
same size, brand, construction and tread pattern.
The tire pressure and wheel alignment should
also be checked and corrected as necessary.
Contact a NISSAN dealer.
Wheel balance
Unbalanced wheels may affect vehicle handling
and tire life. Even with regular use, wheels can get
out of balance. Therefore, they should be bal-
anced as required.
Wheel balance service should be per-
formed with the wheels off the vehicle.
Spin balancing the wheels on the vehicle
could lead to mechanical damage.cFor additional information regarding
tires, refer to “Important Tire Safety In-
formation” (US) or “Tire Safety Informa-
tion” (Canada) in the Warranty Informa-
tion Booklet .
Care of wheels
cWash the wheels when washing the vehicle to
maintain their appearance.
cClean the inner side of the wheels when the
wheel is changed or the underside of the ve-
hicle is washed.
cDo not use abrasive cleaners when washing
the wheels.
cInspect wheel rims regularly for dents or cor-
rosion. Such damage may cause loss of pres-
sure or poor seal at the tire bead.
cNISSAN recommends waxing the road wheels
to protect against road salt in areas where it is
used during winter.
Spare tire (TEMPORARY USE ONLY
spare tire)
Your vehicle may be equipped with a TEMPO-
RARY SPARE USE ONLY spare tire.Observe the following precautions if the TEM-
PORARY USE ONLY spare tire must be used,
Otherwise, your vehicle could be damaged or
involved in an accident:
WARNING
cThe spare tire should be used for emer-
gency use only. It should be replaced
with the standard tire at the first oppor-
tunity to avoid possible tire or differen-
tial damage.
cDrive carefully while the TEMPORARY
USE ONLY spare tire is installed. Avoid
sharp turns and abrupt braking while
driving.
cPeriodically check spare tire inflation
pressure. Always keep the pressure of
the TEMPORARY USE ONLY spare tire
at 60 psi (420 kPa, 4.2 bar) .
cWith the TEMPORARY USE ONLY spare
tire installed do not drive the vehicle at
speeds faster than 50 MPH (80 km/h) .
Maintenance and do-it-yourself8-41
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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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Use the following steps to mount the front license
plate:
1. Remove the two screw gromments from the
glove box.
2. Carefully drill a hole using a 0.39 inch (10
mm) drill bit at each location mark (small
dimple) on the bumper fascia
sA.
3. Insert one grommet into each hole
sB.
4. Insert a small screwdriver into the grommet
to turn the plastic insert.
5. Install the license plate with two M5 x 25 mm
bolts
sC.
CAUTION
cIt is extremely dangerous to ride in a
cargo area inside a vehicle. In a colli-
sion, people riding in these areas are
more likely to be seriously injured or
killed.
cDo not allow people to ride in any area
of your vehicle that is not equipped with
seats and seat belts.
cBe sure everyone in your vehicle is in a
seat and using a seat belt properly.
TERMS
It is important to familiarize yourself with the fol-
lowing terms before loading your vehicle:
cCurb Weight (actual weight of your vehicle) -
vehicle weight including: standard and op-
tional equipment, fluids, emergency tools, and
spare tire assembly. This weightdoes not
include passengers and cargo.
cGVW (Gross Vehicle Weight) - curb weight
plus the combined weight of passengers and
cargo.
cGVWR (Gross Vehicle Weight Rating) - maxi-
mum total weight (load) limit specified for the
vehicle.
WTI0066
INSTALLING FRONT LICENSE PLATE VEHICLE LOADING INFORMATION
Technical and consumer information9-13
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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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Hood release...................3-8
Horn.......................2-23
Hubs
Auto-lock free-running hubs........5-22
I
Ignition switch..................5-7
Important vehicle information label.......9-11
In-cabin microfilter...............8-23
Increasing fuel economy............5-21
Indicator lights and audible reminders
(See warning/indicator lights and audible
reminders).....................2-9
Inside mirror...................3-13
Instrument brightness control.........2-21
Instrument panel.................2-2
Interior light...................2-30
J
Jump seat.....................1-5
Jump starting...................6-9
K
Key ........................3-2
Keyless entry system
(See remote keyless entry system).......3-4L
Labels
Air conditioner specification label.....9-12
Emission control information label.....9-12
Engine serial number............9-11
F.M.V.S.S. certification label........9-11
Vehicle identification number
(VIN) plate..................9-10
Warning labels (for SRS)..........1-17
LATCH (Lower Anchors and Tether for
Children) System................1-38
License plate
Installing the license plate.........9-13
Light
Air bag warning light.........1-17, 2-12
Brake light (See stop light).........8-34
Bulb check/instrument panel........2-9
Bulb replacement..............8-34
Charge warning light............2-11
Front fog light switch............2-22
Headlight aiming adjustment........8-32
Headlight and turn signal switch......2-20
Headlights..................8-31
Interior light.................2-30
Light bulbs..................8-31
Low tire pressure warning light......2-11
Low washer fluid warning light.......2-12
Passenger supplemental air bag
ON/OFF switch and light..........1-15
Spotlights (See map light).........2-32
Warning/indicator lights and audible
reminders...................2-9
Lock
Child safety rear door lock..........3-4Door locks..................3-2
Glove box lock...............2-26
Power door locks...............3-3
Low fuel warning light.............2-11
Low tire pressure warning light........2-11
Low tire pressure warning system........5-3
Luggage rack (see roof rack)..........3-9
Luggage
(See vehicle loading information).......9-13
M
Maintenance
General maintenance............8-2
Inside the vehicle...............8-3
Maintenance precautions..........8-5
Outside the vehicle..............8-2
Seat belt maintenance...........1-28
Under the hood and vehicle.........8-4
Malfunction indicator lamp (MIL)........2-13
Manual front seat adjustment..........1-2
Manual windows................2-30
Map lights....................2-32
Meters and gauges................2-3
Mirror
Inside mirror.................3-13
Outside mirror control........3-14, 3-15
Outside mirrors...............3-14
Vanity mirror.................3-13
Multi-remote control system
(See remote keyless entry system).......3-4
Multi-remote controller battery
replacement...................8-30
10-3
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