engine NISSAN FRONTIER 2004 D22 / 1.G Repair Manual

CHANGING A FLAT TIRE
If you have a flat tire, follow the instructions be-
low.
Stopping the vehicle
1. Safely move the vehicle off the road and
away from traffic.
2. Turn on the hazard warning flashers.
3. Park on a level surface and apply the parking
brake. Shift the manual transmission into R
(Reverse) , or the automatic transmission
into P (Park) .
WARNING
cThe transfer control lever must
be in the 2H, 4H or 4L position.
cDo not leave the transfer control lever in
the N (Neutral) position. Otherwise, the
vehicle could roll unexpectedly even if
the manual transmission is in any gear
or the automatic transmission is in the
P (Park) position. This could result in
serious personal injury or property
damage.
4. Turn off the engine.5. Raise the hood to warn other traffic and to
signal professional road assistance person-
nel that you need assistance.
6. Have all passengers get out of the vehicle
and stand in a safe place, away from traffic
and clear of the vehicle.
WARNING
cMake sure the parking brake is securely
applied and the manual transmission is
shifted into R (Reverse) , or the auto-
matic transmission into P (Park) .
cNever change tires when the vehicle is
on a slope, ice or slippery areas. This is
hazardous.
cNever change tires if oncoming traffic is
close to your vehicle. Wait for profes-
sional road assistance.
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 possible
for tire replacement and/or system re-
setting. (For models with the low tire
pressure warning system)
Blocking wheels
Place suitable blockss1at both the front and
back of the wheel diagonally opposite the flat tire
s2to prevent the vehicle from rolling when it is
jacked up.
WARNING
Be sure to block the wheel as the vehicle
may move and result in personal injury.
WCE0044
In case of emergency6-3
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Type A:
Firmly grasp the center wheel cap and turn either
clockwise or counterclockwise to remove.
Type B:
1. Wrap the end of a screwdriver with a cloth.
2. Pry the center wheel cap off by pushing on
the handle of the screwdriver in the direction
shown.Jacking up vehicle and removing the
damaged tire
WARNING
cNever get under the vehicle while it is
supported only by the jack.
cUse only the jack provided with your
vehicle to lift the vehicle. Do not use the
jack provided with your vehicle on other
vehicles. The jack is designed for lifting
only your vehicle during a tire change.cUse the correct jack-up points. Never
use any other part of the vehicle for jack
support.
cNever jack up the vehicle more than
necessary.
cNever use blocks on or under the jack.
cDo not start or run the engine while
vehicle is on the jack. It may cause the
vehicle to move. This is especially true
for vehicles with limited slip
differentials.
cDo not allow passengers to stay in the
vehicle while it is on the jack.
cNever run the engine with a wheel(s) off
the ground. It may cause the vehicle to
move.
Type B
WCE0071FrontWCE0061
6-6In case of emergency
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COLD pressure: After vehicle has been
parked for three hours or more or driven
less than 1 mile (1.6 km) .
COLD tire pressures are shown on the tire
placard affixed to the inside of the glove
box lid.
5. Securely store the flat tire and jacking equip-
ment in the vehicle.
WARNING
cAlways make sure that the spare tire
and jacking equipment are properly se-
cured after use. Such items can become
dangerous projectiles in an accident or
sudden stop.
cThe spare tire is designed for emer-
gency use. See specific instructions un-
der the heading “Wheels and tires” in
the “Maintenance and do-it-yourself”
section of this manual.
CAUTION
Be sure to center the spare tire suspend-
ing plate on the wheel and then lift the
spare tire.To start your engine with a booster battery, the
instructions and precautions below must be fol-
lowed.
WARNING
cIf done incorrectly, jump starting can
lead to a battery explosion, resulting in
severe injury or death. It could also
damage your vehicle.
cExplosive hydrogen gas is always
present in the vicinity of the battery.
Keep all sparks and flames away from
the battery.
cDo not allow battery fluid to come into
contact with eyes, skin, clothing or
painted surfaces. Battery fluid is a cor-
rosive sulfuric acid solution which can
cause severe burns. If the fluid should
come into contact with anything, imme-
diately flush the contacted area with
water.
cKeep battery out of the reach of
children.
cThe booster battery must be rated at 12
volts. Use of an improperly rated battery
can damage your vehicle.cWhenever working on or near a battery,
always wear suitable eye protectors (for
example, goggles or industrial safety
spectacles) and remove rings, metal
bands, or any other jewelry. Do not lean
over the battery when jump starting.
cDo not attempt to jump start a frozen
battery. It could explode and cause se-
rious injury.
cYour vehicle has an automatic engine
cooling fan. It could come on at any
time. Keep hands and other objects
away from it.
JUMP STARTING
In case of emergency6-9
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WARNING
Always follow the instructions below.
Failure to do so could result in damage to
the charging system and cause personal
injury.
1. If the booster battery is in another vehicle,
position the two vehicles to bring their bat-
teries near each other.
Do not allow the two vehicles to touch.2. Apply the parking brake. Move the shift lever
to N (Neutral) (manual transmission) or to P
(Park) (automatic transmission) . Switch off
all unnecessary electrical systems (lights,
heater, air conditioner, etc.) .
3. Remove vent caps on the battery (if so
equipped) . Cover the battery with an old
cloth to reduce explosion hazard.
4. Connect jumper cables in the sequence il-
lustrated (
sA,sB,sC,sD).
CAUTION
cAlways connect positive (1) to positive
(1) and negative (2) to body ground (for
example, strut mounting bolt, engine
lift bracket, etc.) — not to the battery.
cMake sure the jumper cables do not
touch moving parts in the engine com-
partment and that the cable clamps do
not contact any other metal.
5. Start the engine of the booster vehicle and
let it run for a few minutes.
6. Keep the engine speed of the booster ve-
hicle at about 2,000 rpm, and start the en-
gine of the vehicle being jump started.
CAUTION
Do not keep the starter motor engaged for
more than 10 seconds. If the engine does
not start right away, turn the key off and
wait 3 to 4 seconds before trying again.
7. After starting the engine, carefully discon-
nect the negative cable and then the positive
cable.
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6-10In case of emergency
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8. Replace the vent caps (if so equipped) . Be
sure to dispose of the cloth used to cover
the vent holes as it may be contaminated
with corrosive acid.WARNING
cAutomatic transmission models cannot
be push-started or tow-started. At-
tempting to do so may cause transmis-
sion or other vehicle 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 engine
damage or a vehicle 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.
PUSH STARTING IF YOUR VEHICLE OVERHEATS
In case of emergency6-11
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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. Do not open the
hood further until no steam or coolant can be
seen.
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.
WARNING
Be careful not to allow your hands, hair,
jewelry or clothing to come into contact
with, or get caught in, engine belts or the
engine cooling fan. The engine cooling
fan can start at any time when the coolant
temperature is high.
7. After the engine cools down, check the cool-
ant level in the engine coolant reservoir tank
with the engine running. Add coolant to the
engine coolant reservoir tank if necessary.
Have your vehicle repaired at a NISSAN
dealer.When towing your vehicle, all State (Provincial in
Canada) and local regulations for towing must be
followed. Incorrect towing equipment could dam-
age your vehicle. Towing instructions are avail-
able from a NISSAN dealer. Local service opera-
tors are generally familiar with the applicable laws
and procedures for towing. To assure proper
towing and to prevent accidental damage to your
vehicle, NISSAN recommends having a service
operator tow your vehicle. It is advisable to have
the service operator carefully read the following
precautions:
WARNING
cNever ride in a vehicle that is being
towed.
cNever get under your vehicle after it has
been lifted by a tow truck.
CAUTION
cWhen towing, make sure that the trans-
mission, axles, steering system and
powertrain are in working condition. If
any unit is damaged, dollies must be
used.
cAlways attach safety chains before
towing.
TOWING YOUR VEHICLE
6-12In case of emergency
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8 Maintenance and do-it-yourself
Maintenance requirements..........................8-2
General maintenance..............................8-2
Explanation of general maintenance items.........8-2
Maintenance precautions...........................8-5
Engine compartment check locations................8-6
Engine cooling system.............................8-9
Checking engine coolant level...................8-9
Changing engine coolant.......................8-10
Engine oil........................................8-10
Checking engine oil level.......................8-10
Changing engine oil...........................8-11
Changing engine oil filter.......................8-13
Automatic transmission fluid.......................8-14
Temperature conditions for checking.............8-14
Power steering fluid...............................8-16
Brake and clutch fluid.............................8-16
Brake fluid....................................8-17
Clutch fluid...................................8-17
Window washer fluid.............................8-18
Window washer fluid reservoir..................8-18
Battery..........................................8-18
Jump starting.................................8-20
Drive belts.......................................8-20Spark plugs......................................8-21
Replacing spark plugs.........................8-21
Air cleaner.......................................8-23
In-cabin Microfilter (if so equipped)..............8-24
Windshield wiper blades..........................8-26
Cleaning.....................................8-26
Replacing....................................8-26
Parking brake and brake pedal.....................8-27
Checking parking brake........................8-27
Checking brake pedal..........................8-27
Brake booster.................................8-28
Fuses...........................................8-29
Passenger compartment.......................8-29
Keyfob battery replacement........................8-30
Lights...........................................8-31
Headlights....................................8-31
Fog lights (if so equipped)......................8-32
Exterior and interior lights.......................8-33
Wheels and tires.................................8-36
Tire pressure..................................8-36
Tire labeling...................................8-39
Types of tires..................................8-42
Tire chains....................................8-42
Changing wheels and tires.....................8-43
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Your new NISSAN has been designed to have
minimum maintenance requirements with longer
service intervals to save you both time and
money. However, some day-to-day and regular
maintenance is essential to maintain your NIS-
SAN’s good mechanical condition, as well as its
emission and engine performance.
It is the owner’s responsibility to make sure that
the scheduled maintenance, as well as general
maintenance, is performed.
As the vehicle owner, you are the only one who
can ensure that your vehicle receives proper
maintenance. You are a vital link in the mainte-
nance chain.
Scheduled maintenance
For your convenience, both required and optional
scheduled maintenance items are described and
listed in your “NISSAN Service and Maintenance
Guide.” You must refer to that guide to ensure
that necessary maintenance is performed on your
NISSAN at regular intervals.
General maintenance
General maintenance includes those items which
should be checked during normal day-to-day op-
eration. They are essential for proper vehicle op-
eration. It is your responsibility to perform these
maintenance procedures regularly as prescribed.Performing general maintenance checks requires
minimal mechanical skill and only a few general
automotive tools.
These checks or inspections can be done by you,
a qualified technician, or, if you prefer, a NISSAN
dealer.
Where to go for service
If maintenance service is required or your vehicle
appears to malfunction, have the systems
checked and corrected by a NISSAN dealer.
NISSAN technicians are well-trained specialists
who are kept up-to-date with the latest service
information through technical bulletins, service
tips, and in-dealership training programs. They
are completely qualified to work on NISSAN ve-
hiclesbeforethey work on your vehicle, rather
than after they have worked on it.
You can be confident that a NISSAN dealer’s
service department performs the best job to meet
the maintenance requirements on your vehicle —
in a reliable and economic way.During the normal day-to-day operation of the
vehicle, general maintenance should be per-
formed regularly as prescribed in this section. If
you detect any unusual sounds, vibrations or
smells, be sure to check for the cause or have a
NISSAN dealer do it promptly. In addition, you
should notify a NISSAN dealer if you think that
repairs are required.
When performing any checks or maintenance
work, closely observe the “Maintenance precau-
tions” later in this section.
EXPLANATION OF GENERAL
MAINTENANCE ITEMS
Additional information on the following
items with “*” is found later in this section.
Outside the vehicle
The maintenance items listed here should be
performed from time to time, unless otherwise
specified.
Doors, engine hood and tailgateCheck that
the doors, engine hood and tailgate operate
properly. Also ensure that all latches lock se-
curely. Lubricate hinges, latches, latch pins, roll-
ers and links as necessary. Make sure that the
secondary latch keeps the hood from opening
when the primary latch is released.
MAINTENANCE REQUIREMENTS GENERAL MAINTENANCE
8-2Maintenance and do-it-yourself
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Warning lights and chimesMake sure all
warning lights and chimes are operating properly.
Windshield wiper and washer*Check that
the wipers and washer operate properly and that
the wipers do not streak.
Windshield defrosterCheck that the air
comes out of the defroster outlets properly and in
sufficient quantity when operating the heater or
air conditioner.
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) .
Automatic transmission fluid level*Check
the level after putting the selector lever in P with
the engine idling at operating temperature.
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.
Brake and clutch fluid levels*Make sure that
the brake and clutch fluid level is between the
MIN and MAX lines on the reservoir.
Engine coolant level*Check the coolant level
when the engine is cold.Engine drive belts*Make sure the drive belts
are not frayed, worn, cracked or oily.
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.
Exhaust systemMake sure there are no loose
supports, cracks or holes. If the sound of the
exhaust seems unusual or there is a smell of
exhaust 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.
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.
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.
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.
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.
Windshield washer fluid*Check that there is
adequate fluid in the reservoir.
8-4Maintenance and do-it-yourself
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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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