ENGINE

EM
A

EM
SECTION
ENGINE MECHANICAL C

D

E
CONTENTS
QR25DE Removal and Installation .........................................17 F

PRECAUTION ............................................... 4 SPARK PLUG ................................................... 18
Exploded View .........................................................18
G
PRECAUTIONS ................................................... 4 Removal and Installation .........................................18
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- CAMSHAFT VALVE CLEARANCE .................. 20
SIONER" ................................................................... 4 Valve Clearance ......................................................20 H
Precaution for Drain Engine Coolant ......................... 4
COMPRESSION PRESSURE ........................... 23
Precaution for Disconnecting Fuel Piping ................. 4
Compression Pressure ............................................23
Precaution for Removal and Disassembly ................ 4 I
Precaution for Inspection, Repair and Replace- REMOVAL AND INSTALLATION ............... 25
ment .......................................................................... 4
Precaution for Assembly and Installation .................. 5 AIR CLEANER AND AIR DUCT ....................... 25 J
Parts Requiring Angle Tightening ............................. 5 Exploded View .........................................................25
Precaution for Liquid Gasket ..................................... 5 Removal and Installation .........................................25

PREPARATION ............................................ 7 INTAKE MANIFOLD ......................................... 27 K
Exploded View .........................................................27
PREPARATION ................................................... 7 Removal and Installation .........................................27
Special Service Tool ................................................. 7 L
Commercial Service Tool .......................................... 9 EXHAUST MANIFOLD AND THREE WAY
CATALYST ........................................................ 31
SYSTEM DESCRIPTION ............................. 12 Exploded View .........................................................31
Removal and Installation .........................................31 M
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................12 OIL PAN ............................................................ 33
NVH Troubleshooting - Engine Noise ..................... 12 Exploded View .........................................................33 N
Use the Chart Below to Help You Find the Cause Removal and Installation .........................................33
of the Symptom ....................................................... 13
IGNITION COIL ................................................. 36
PERIODIC MAINTENANCE ......................... 14 Exploded View .........................................................36 O
Removal and Installation .........................................36
DRIVE BELTS ....................................................14
Exploded View ........................................................ 14 ROCKER COVER ............................................. 37 P
Checking Drive Belts ............................................... 14 Exploded View .........................................................37
Adjustment .............................................................. 14 Removal and Installation .........................................37
Removal and Installation ......................................... 14
Removal and Installation of Drive Belt Auto-Ten- FUEL INJECTOR AND FUEL TUBE ................ 39
sioner ...................................................................... 15 Exploded View .........................................................39
Removal and Installation .........................................39
AIR CLEANER FILTER ......................................17

Revision: August 2014 EM-1 2015 Frontier NAM

INTAKE VALVE TIMING CONTROL ................. 44 PREPARATION ......................................... 122
Intake Valve Timing Control Solenoid Valve .......... 44
PREPARATION ................................................ 122
TIMING CHAIN .................................................. 45 Special Service Tool ............................................. 122
Exploded View ........................................................ 45 Commercial Service Tool ...................................... 124
Removal and Installation ........................................ 46
SYSTEM DESCRIPTION .......................... 127
CAMSHAFT ....................................................... 54
Exploded View ........................................................ 54 NOISE, VIBRATION AND HARSHNESS
Removal and Installation ........................................ 54 (NVH) TROUBLESHOOTING ........................... 127
NVH Troubleshooting - Engine Noise ................... 127
OIL SEAL ........................................................... 63 Use the Chart Below to Help You Find the Cause
Removal and Installation of Valve Oil Seal ............. 63 of the Symptom ..................................................... 127
Removal and Installation of Front Oil Seal ............. 63
Removal and Installation of Rear Oil Seal .............. 65 PERIODIC MAINTENANCE ...................... 129
CYLINDER HEAD .............................................. 67 DRIVE BELTS .................................................. 129
Exploded View ........................................................ 67 Exploded View ...................................................... 129
Removal and Installation ........................................ 67 Checking Drive Belts ............................................. 129
Exploded View ........................................................ 70 Adjustment ............................................................ 129
Disassembly and Assembly .................................... 70 Removal and Installation ....................................... 129
Inspection After Disassembly ................................. 72 Drive Belt Auto-Tensioner and Idler Pulley ........... 130

UNIT REMOVAL AND INSTALLATION ..... 77 AIR CLEANER FILTER .................................... 131
Exploded View ...................................................... 131
ENGINE ASSEMBLY ......................................... 77 Removal and Installation ....................................... 131
Exploded View ........................................................ 77
Removal and Installation ........................................ 77 SPARK PLUG ................................................... 132
Exploded View ...................................................... 132
UNIT DISASSEMBLY AND ASSEMBLY ... 80 Removal and Installation ....................................... 132
ENGINE UNIT .................................................... 80 CAMSHAFT VALVE CLEARANCE ................. 134
Exploded View ........................................................ 80 Valve Clearance .................................................... 134
Disassembly and Assembly .................................... 81
Inspection After Disassembly ................................. 91 COMPRESSION PRESSURE .......................... 138
Compression Pressure ......................................... 138
HOW TO SELECT PISTON AND BEARING ... 101
How to Select Piston and Bearing .........................101 REMOVAL AND INSTALLATION ............. 140
SERVICE DATA AND SPECIFICATIONS ENGINE ROOM COVER .................................. 140
(SDS) .......................................................... 108 Removal and Installation ....................................... 140

SERVICE DATA AND SPECIFICATIONS AIR CLEANER AND AIR DUCT ....................... 141
(SDS) ................................................................ 108 Exploded View ...................................................... 141
Standard and Limit ................................................108 Removal and Installation ....................................... 141
VQ40DE INTAKE MANIFOLD COLLECTOR ................. 142
Exploded View ...................................................... 142
PRECAUTION ............................................ 119 Removal and Installation ....................................... 142
PRECAUTIONS ............................................... 119 INTAKE MANIFOLD ......................................... 145
Precaution for Supplemental Restraint System
Exploded View ...................................................... 145
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Removal and Installation ....................................... 145
SIONER" ................................................................119
Precaution for Drain Engine Coolant .....................119 EXHAUST MANIFOLD AND THREE WAY
Precaution for Disconnecting Fuel Piping ..............119 CATALYST ....................................................... 147
Precaution for Removal and Disassembly .............119 Exploded View ...................................................... 147
Precaution for Inspection, Repair and Replace- Removal and Installation (Three Way Catalyst) .... 147
ment .......................................................................119 Removal and Installation (Exhaust Manifold) ........ 148
Precaution for Assembly and Installation ..............120
Parts Requiring Angle Tightening ..........................120 OIL PAN AND OIL STRAINER ........................ 151
Precaution for Liquid Gasket .................................120 Exploded View ...................................................... 151

Revision: August 2014 EM-2 2015 Frontier NAM

Removal and Installation ....................................... 151 CAMSHAFT ..................................................... 192
Exploded View ....................................................... 192 A
IGNITION COIL ................................................ 157 Removal and Installation ....................................... 193
Exploded View ...................................................... 157
Removal and Installation ....................................... 157 OIL SEAL ........................................................ 202
EM
Removal and Installation of Valve Oil Seal ............ 202
ROCKER COVER ............................................. 158 Removal and Installation of Front Oil Seal ............ 202
Exploded View ...................................................... 158 Removal and Installation of Rear Oil Seal ............. 203
Removal and Installation ....................................... 158 C
CYLINDER HEAD ........................................... 205
FUEL INJECTOR AND FUEL TUBE ............... 162 Exploded View ....................................................... 205
Exploded View ...................................................... 162 Removal and Installation ....................................... 205
Removal and Installation ....................................... 162 D
Exploded View ....................................................... 209
INTAKE VALVE TIMING CONTROL ............... 167 Disassembly and Assembly ................................... 209
Inspection After Disassembly ................................ 211
Intake Valve Timing Control Solenoid Valve (LH).. 167 E
Intake Valve Timing Control Solenoid Valve (RH).. 167 UNIT REMOVAL AND INSTALLATION .... 216
FRONT TIMING CHAIN CASE ......................... 168 ENGINE ASSEMBLY ...................................... 216
Exploded View ...................................................... 168 F
Exploded View ....................................................... 216
Removal and Installation ....................................... 168
Removal and Installation ....................................... 216
TIMING CHAIN ................................................. 176
UNIT DISASSEMBLY AND ASSEMBLY . 219 G
Exploded View ...................................................... 176
Removal and Installation ....................................... 176 ENGINE UNIT .................................................. 219
Exploded View ....................................................... 219
TIMING CHAIN TENSIONER ........................... 184 H
Disassembly and Assembly ................................... 220
Exploded View ...................................................... 184
Inspection After Disassembly ................................ 230
Removal and Installation (Primary Timing Chain
Dowel Pin Alignment ............................................. 241
Tensioner) ............................................................. 184 I
Removal and Installation (Secondary Timing HOW TO SELECT PISTON AND BEARING .. 243
Chain Tensioner) ................................................... 185 How to Select Piston and Bearing ......................... 243
Removal and Installation (Secondary Timing
J
Chain Tensioner Shoe) ......................................... 185 SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 248
REAR TIMING CHAIN CASE ........................... 187
Exploded View ...................................................... 187 SERVICE DATA AND SPECIFICATIONS K
Removal and Installation ....................................... 187 (SDS) ............................................................... 248
Standard and Limit ................................................ 248
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Revision: August 2014 EM-3 2015 Frontier NAM

PRECAUTIONS
< PRECAUTION > [QR25DE]

PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000010709630

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING:
• 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 performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
• 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 har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s) with a
hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery and wait at least three minutes before performing any service.
Precaution for Drain Engine Coolant INFOID:0000000010709631

Drain engine coolant when engine is cooled.
Precaution for Disconnecting Fuel Piping INFOID:0000000010709632

• Before starting work, make sure no fire or spark producing items are in the work area.
• Release fuel pressure before disconnecting and disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.
Precaution for Removal and Disassembly INFOID:0000000010709633

• When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Cover openings of engine system with tape or equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
• 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
in the step.
Precaution for Inspection, Repair and Replacement INFOID:0000000010709634

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.

Revision: August 2014 EM-4 2015 Frontier NAM

PRECAUTIONS
< PRECAUTION > [QR25DE]
Precaution for Assembly and Installation INFOID:0000000010709635

A
• Use torque wrench to tighten bolts or nuts to specification.
• 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 specified, EM
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage. C
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• Release air within route when refilling after draining engine coolant. D
• Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped).
Then make sure that there are no leaks at fuel line connections.
• After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gasses for leakage. E

Parts Requiring Angle Tightening INFOID:0000000010709636

• For the final tightening of the following engine parts use Tool: F

Tool number : KV10112100 (BT-8653-A)
G
- Cylinder head bolts
- Lower cylinder block bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No angle wrench is required as bolt flange is provided with notches for angle tighten- H
ing)
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step. I
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000010709637

J
REMOVAL OF LIQUID GASKET
• After removing the bolts and nuts, separate the mating surface and
remove the old liquid gasket using Tool. K

Tool number : KV10111100 (J-37228)
CAUTION: L
Do not damage the mating surfaces.
• Tap the seal cutter to insert it (1).
• In areas where the Tool is difficult to use, lightly tap to slide it (2). M

WBIA0566E

N
LIQUID GASKET APPLICATION PROCEDURE
1. Remove the old liquid gasket adhering to the gasket application
surface and the mating surface using suitable tool.
O
• Remove the liquid gasket completely from the groove of the
liquid gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign material. P

PBIC0003E

Revision: August 2014 EM-5 2015 Frontier NAM

PRECAUTIONS < PRECAUTION > [QR25DE] 3. SEM159F CAUTION: If there are more specific instructions in the procedures contained in this manual concerning liq- uid gasket application. install the mat- ing component. • Normally apply the liquid gasket on the inside edge of the bolt holes. Refer to GI-21. Use Genuine RTV Silicone Sealant or equivalent. Revision: August 2014 EM-6 2015 Frontier NAM . "Recommended Chemical Products and Sealants". 4. WBIA0567E • If there is a groove for the liquid gasket application. • If the liquid gasket protrudes. • Wait 30 minutes or more after installation before refilling the engine with oil or coolant. wipe it off immediately. Attach the liquid gasket tube to the suitable tool. observe them. Apply the liquid gasket without breaks to the specified location with the specified dimensions. • Do not retighten after the installation. Also apply to the outside edge of the bolt holes when specified in the procedure. apply the liquid gasket to the groove. • Within five minutes of liquid gasket application.

KV10115900 G (J-26336-20) Attachment 2. PREPARATION < PREPARATION > [QR25DE] PREPARATION A PREPARATION Special Service Tool INFOID:0000000010709638 EM The actual shape of the tools may differ from those illustrated here.) C Tool name KV10111100 Removing oil pan and front cover. 1. KV10109220 ( — ) H Adapter PBIC1650E KV10112100 Tightening bolts for cylinder head. etc. but Part (2) is not so. Tool number Description (TechMate No.87 in) width hexagon nut Heated oxygen sensor wrench L NT379 M KV10107902 Replacing valve oil seal (J-38959) Valve oil seal puller N O NT011 KV10115600 Installing valve oil seal (J-38958) P Valve oil seal drift NT024 Revision: August 2014 EM-7 2015 Frontier NAM . main bear- (BT-8653-A) ing cap and connecting rod cap I Angle wrench J AWBIA1043ZZ KV10117100 Loosening or tightening air fuel ratio sensor 1 K (J-36471-A) For 22 mm (0. (J-37228) D Seal cutter E S-NT046 F KV10116200 Disassembling valve mechanism (J-26336-A) Part (1) is a component of KV10116200 (J- Valve spring compressor 26336-A).

PREPARATION < PREPARATION > [QR25DE] Tool number Description (TechMate No.87 in) NT636 KV11105210 Lock drive plate (J-44716) Stopper plate AWBIA1811ZZ Revision: August 2014 EM-8 2015 Frontier NAM .87 in) LBIA0444E KV10114400 Loosening or tightening heated oxygen sen- (J-38365) sor 1 Heated oxygen sensor wrench a: 22 mm (0.) Tool name EM03470000 Installing piston assembly into cylinder bore (J-8037) Piston ring compressor NT044 ST16610001 Removing pilot bushing (M/T models) or pilot (J-23907) converter (A/T models) Pilot bushing puller NT045 16441 6N210 Removing fuel tube quick connectors in en- (J-45488) gine room. Quick connector release PBIC0198E — Releasing drive belt tension (J-46535) Drive belt tension releaser WBIA0536E KV991J0050 Loosening or tightening air fuel ratio A/F sen- (J-44626) sor Air fuel sensor Socket a: 22 mm (0.

PREPARATION < PREPARATION > [QR25DE] Commercial Service Tool INFOID:0000000010709639 A (TechMate No.) Description Tool name EM ( — ) Loosening nuts. Cylinder head bolt wrench and used with the angle wrench [SST: KV10112100 (BT8653-A)] a: 13 (0. Adapter M ZZA0008D N (J-24239-01) Loosening and tightening cylinder head bolt.39) Unit: mm (in) P NT583 Revision: August 2014 EM-9 2015 Frontier NAM .47) c: 10 (0. screws and bolts Power tool C D PIIB1407E ( — ) Removing and installing spark plug Spark plug wrench E F PBIC2982E ( — ) Removing and installing crankshaft pulley G Pulley holder H ZZA1010D I ( — ) Removing crankshaft pulley Pulley puller J K NT676 ( — ) Checking compression pressure 1. Compression tester L 2.51) dia. O b: 12 (0.

S-NT015 ( — ) 1: Reaming valve guide inner hole Valve guide reamer 2: Reaming hole for oversize valve guide Intake and Exhaust: d1: 6.0 mm (0. S-NT016 Revision: August 2014 EM-10 2015 Frontier NAM .2 mm (0.06 in) PBIC2072E ( — ) Removing and installing piston ring Piston ring expander S-NT030 ( — ) Removing and installing valve guide Valve guide drift Intake and Exhaust: a: 9.) Description Tool name ( — ) Finishing valve seat dimensions Valve seat cutter set S-NT048 ( — ) Removing and installing flywheel Socket Size: T55 PBIC1113E (J-45816) Removing and installing AT drive plate bolts E20 ®Socket LBIA0285E ( — ) Removing and installing oil pressure switch Deep socket a: 27 mm (1. PREPARATION < PREPARATION > [QR25DE] (TechMate No.402 in) dia. d2: 10.374 in) dia.217 in) dia.5 mm (0.5 mm (0.236 in) dia. b: 5.

) EM a = 18 mm (0. for zirconia heated oxygen sensor b = 12 mm (0.e. PREPARATION < PREPARATION > [QR25DE] (TechMate No. for titania heated oxygen sensor C AEM488 ( — ) Lubricating oxygen sensor thread cleaning Anti-seize lubricant i.71 in) dia.) Description Tool name A a: (J-43897-18) Reconditioning the exhaust system threads b: (J-43897-12) before installing a new heated oxygen sensor Oxygen sensor thread cleaner (Use with anti-seize lubricant shown below.: (PermatexTM tool when reconditioning exhaust system D 133AR or equivalent meeting MIL threads specification MIL-A-907) E AEM489 F ( — ) Pressing the tube of liquid gasket Tube presser G H NT052 I J K L M N O P Revision: August 2014 EM-11 2015 Frontier NAM .47 in) dia.

Engine Noise INFOID:0000000010709640 PBIC2983E Revision: August 2014 EM-12 2015 Frontier NAM . VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING < SYSTEM DESCRIPTION > [QR25DE] SYSTEM DESCRIPTION NOISE. NOISE. VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting .

C Operating condition of engine Location Type of Before After When Source of Refer- When When While Check item D of noise noise warm. 3. Specify the operating condition of engine. Locate the area where noise occurs. Piston ring side clear- Slap or Piston EM-91 ley A — — B B A ance rap slap noise EM-91 Cylinder Piston ring end gap EM-91 block Connecting rod bend I (Side of and torsion engine) Connect. 2. start. warm. repair or replace these parts. VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING < SYSTEM DESCRIPTION > [QR25DE] Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000010709641 A 1. NOISE. Connecting rod bushing Oil pan ing rod oil clearance EM-91 Knock A B C B B B J bearing Connecting rod bearing EM-91 noise oil clearance Main bearing oil clear- Main bear. EM-91 K Knock A B — A B C ance ing noise EM-91 Crankshaft runout Timing Front of Timing chain cracks chain and L engine Tapping or and wear EM-46 A A — B B B chain ten- Front cov. clearance H EM-91 shaft pul. Confirm the type of noise. ticking Timing chain tensioner EM-46 sioner er operation noise M Drive belt Squeak- (Sticking ing or fizz. EM 4. Check specified noise source. Ticking or Tappet C A — A B — Valve clearance EM-108 E gine clicking noise Rocker cover Camshaft Camshaft journal oil EM-54 Cylinder Rattle C A — A B C bearing clearance EM-54 head noise Camshaft runout F Piston to piston pin oil Slap or Piston pin clearance EM-91 — A — B B — knock noise Connecting rod bushing EM-91 G oil clearance Piston to cylinder bore Crank. A B — B — B Drive belt deflection or slip- ing EM-14 ping) N Front of Drive belt Idler pulley bearing op- engine Creaking A B A B A B (Slipping) eration Water O Squall A B — B A B pump Water pump operation CO-21 Creak noise A: Closely related B: Related C: Sometimes related —: Not related P Revision: August 2014 EM-13 2015 Frontier NAM . noise ence page idling racing driving up up ing Top of en. If necessary.

If the indicator is out of allowable working range or drive belt is damaged. Idler pulley 9. Visually check entire belt for wear. Refer to EM-141. 1. 4. Drive belt auto. Make sure that the auto-tensioner indicator is within the allowable working range. 2. damage or cracks. DRIVE BELTS < PERIODIC MAINTENANCE > [QR25DE] PERIODIC MAINTENANCE DRIVE BELTS Exploded View INFOID:0000000010709642 LBIA0438E 1. The drive belt tension is automatically adjusted by the drive belt auto-tensioner. Water pump 8. Crankshaft pulley 5. Adjustment INFOID:0000000010709644 There is no manual drive belt tension adjustment. Power steering oil pump pulley 3. A/C compressor (with A/C) 6. replace the drive belt. Removal and Installation INFOID:0000000010709645 REMOVAL Revision: August 2014 EM-14 2015 Frontier NAM . Allowable working range Checking Drive Belts INFOID:0000000010709643 WARNING: Be sure to perform when the engine is stopped. "Removal and Installation". "Removal and Installation". Remove air duct and resonator assembly when inspecting drive belt. 3. Idler pulley Idler pulley (without A/C) 7.tensioner A. Drive belt 2. Refer to EM-129. Generator pulley 4.

Partially drain engine coolant. 5. (Do not turn it counterclockwise. 3. I Removal and Installation of Drive Belt Auto-Tensioner INFOID:0000000010709646 J K L M N LBIA0440E O REMOVAL NOTE: P When removing components such as hoses. WARNING: • Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes F off. Remove air cleaner and air duct. 1. G • Confirm belts are completely set on the pulleys. CAUTION: • Do not loosen the auto-tensioner pulley bolt. Revision: August 2014 EM-15 2015 Frontier NAM . Refer to EM-14. CAUTION: C • Do not loosen the auto-tensioner pulley bolt. Disconnect battery negative terminal. including LBIA0439E pulley. the com- plete auto-tensioner must be replaced as a unit. "Changing Engine Coolant". DRIVE BELTS < PERIODIC MAINTENANCE > [QR25DE] 1. 4. INSTALLATION E Installation is in the reverse order of removal.) If turned counterclockwise.. • Check that there is no engine oil or engine coolant on the drive belt or pulley grooves. Remove drive belt. 2. Install Tool on auto-tensioner pulley bolt and move in the direc- tion of arrow (loosening direction of tensioner). Refer to CO-12. (Do not turn it counterclockwise. Remove drive belt. • Confirm tension of drive belt indicator (fixed side) is within the allowable working range. D 2. "Removal and Installation". NOTE: H • Turn crankshaft pulley clockwise several times to equalize tension between each pulley. A Tool number : — (J-46535) WARNING: EM • Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. including pulley. Refer to PG-89. "Removal and Installation". cap or plug openings to prevent fluid from spill- ing. Refer to EM-25. the complete auto-tensioner must be replaced as a unit. Disconnect upper radiator hose from radiator. etc. "Removal and Installation". tubes/lines.) If turned counter- clockwise.

10. Revision: August 2014 EM-16 2015 Frontier NAM . "Exploded View". Remove generator. Remove drive belt auto-tensioner.QR25DE Models". Disconnect coolant reservoir hose from radiator. Refer to ST-19. Remove lower and upper shrouds. Refer to CHG-28. CAUTION: If there is damage greater than peeled paint. Refer to CO-16. replace drive belt auto-tensioner. DRIVE BELTS < PERIODIC MAINTENANCE > [QR25DE] 6. INSTALLATION Installation is in the reverse order of removal. 7. Remove the power steering oil pump and position aside. 9. "Removal and Installation". "Removal and Installation . 8.

2. Remove air cleaner filter. C D E LBIA0442E INSTALLATION F Installation is in the reverse order of removal. AIR CLEANER FILTER < PERIODIC MAINTENANCE > [QR25DE] AIR CLEANER FILTER A Removal and Installation INFOID:0000000010709647 REMOVAL EM 1. G H I J K L M N O P Revision: August 2014 EM-17 2015 Frontier NAM . Unfasten clips and lift up air cleaner case (upper).

PBIC2996E INSPECTION AFTER REMOVAL Revision: August 2014 EM-18 2015 Frontier NAM . Spark plug 3. 2. Ignition coil 2. Refer to EM-36. REMOVAL 1. CAUTION: Be sure to use the correct socket to remove the spark plugs. An incorrect socket can damage the spark plugs. Remove the ignition coil. SPARK PLUG < PERIODIC MAINTENANCE > [QR25DE] SPARK PLUG Exploded View INFOID:0000000010709648 PBIC2995E 1. Rocker cover Removal and Installation INFOID:0000000010709649 WARNING: Be sure the engine and ignition switch are off and that the parking brake is engaged securely. CAUTION: Do not drop or shock it. Remove the spark plug using a suitable tool.

M N O P Revision: August 2014 EM-19 2015 Frontier NAM . G H SMA806CA I INSTALLATION Installation is in the reverse order of removal. Cleaner air pressure : Less than 588 kPa (6 kg/cm2. A EM C SMA773C D • If the spark plug tip is covered with carbon. spark plug cleaner may be used. K Make NGK Standard type* PLZKAR6A-11 Gap (nominal) 1.1 mm (0. 85 psi) E Cleaning time : Less than 20 seconds • Checking and adjusting spark plug gap is not required between F change intervals. J CAUTION: Do not drop or shock the spark plug.043 in) L * : Always check with the Parts Department for the latest parts information. SPARK PLUG < PERIODIC MAINTENANCE > [QR25DE] • Do not use a wire brush for cleaning.

SEM139D Valve clearance: Unit: mm (in) Cold 1 (reference data) Hot 2 (reference data) Intake 0.0.0.0. Remove radiator shroud (lower). CAMSHAFT VALVE CLEARANCE < PERIODIC MAINTENANCE > [QR25DE] CAMSHAFT VALVE CLEARANCE Valve Clearance INFOID:0000000010709650 INSPECTION Perform the following inspection after removal. installation or replacement of camshaft or valve-related parts. 1 cylinder at TDC of its compression stroke.308 . PBIC3015E • Make sure that intake and exhaust cam noses of No.013) 0. "Exploded View".0.26 . Measure the valve clearance as follows: a.010 . • Rotate crankshaft pulley clockwise and align TDC mark to tim- ing indicator on front cover. KBIA0400J b. 1 cylin- der are located as shown.012 . 1.32 (0.34 (0.304 .0.0.24 . • If not. idling or noise). Use a feeler gauge to measure the clearance between valve lifter and camshaft.009 . Set No. Remove rocker cover. Refer to EM-37. Refer to CO-16. rotate crankshaft one revolution (360°) and align as shown.0.013) 0. "Removal and Installation".432 (0.012 .016) Exhaust 0. 2. or if there are unusual engine conditions due to changes in valve clearance over time (starting. 3.0.017) 1 : Approximately 20°C (68°F) 2: Approximately 80°C (176°F) Revision: August 2014 EM-20 2015 Frontier NAM .416 (0.

3 CYL. 1 CYL. 3 CYL. Use the equation below to calculate valve lifter thickness for replacement. Refer to EM-54. CAMSHAFT VALVE CLEARANCE < PERIODIC MAINTENANCE > [QR25DE] • Measure the valve clearances at locations marked “×” as shown in the table below (locations indicated with black arrow A shown) with feeler gauge. perform adjustment. E F G PBIC3015E • Measure the valve clearance at locations marked “×” as shown H in the table below (locations indicated with black arrow shown) with feeler gauge. M 3. 2. Remove camshaft. 2 CYL. No. ADJUSTMENT L • Perform adjustment depending on selected head thickness of valve lifter. Measure the center thickness of the removed valve lifters with a micrometer. Revision: August 2014 EM-21 2015 Frontier NAM . 4 cylinder at INT × × compression TDC J EXH × × PBIC3026E K 4. No. Measure the valve clearance. • No. 2 CYL. 1 CYL. No. Rotate crankshaft one revolution (360°) and align TDC mark to timing indicator on front cover. 1 cylinder at INT × × compression TDC EXH × × C PBIC3017E D c. No. No. 4 CYL. 1 cylinder compression TDC EM Measuring position No. No. N O P KBIA0057E 5. 4. 1. • No. 4 cylinder compression TDC I Measuring position No. 4 CYL. No. No. Remove valve lifters at the locations that are out of the standard. If out of standard. "Removal and Installation".

CAMSHAFT VALVE CLEARANCE < PERIODIC MAINTENANCE > [QR25DE] Valve lifter thickness calculation: t = t1 + (C1 – C2) t = Valve lifter thickness to be replaced t1 = Removed valve lifter thickness C1 = Measured valve clearance C2 = Standard valve clearance: Intake : 0. 6.2740 to 0.02 mm (0.0008 in) (when manufactured at factory). Install the selected valve lifter. "Removal and Installation".011 in) Exhaust : 0. Make sure that the valve clearances for cold engine are within specifications by referring to the specified values. Revision: August 2014 EM-22 2015 Frontier NAM . and check for unusual noise and vibration. Start the engine. "Standard and Limit". Install camshaft. Refer to EM-108.46 mm (0. 8. Stamp mark “696” indicates 6. 10.96 mm (0. Refer to EM-54. 7.012 in) • Thickness of new valve lifter can be identified by stamp marks on the reverse side (inside the cylinder). Manually rotate crankshaft pulley a few rotations.28 mm (0.2740 in) in thickness.30 mm (0.2937 in) in steps of 0. KBIA0119E NOTE: Available thickness of valve lifter: 26 sizes range 6.96 to 7. Installation of the remaining components is in the reverse order of removal. 11. 9.

psi) /rpm P Standard Minimum Differential limit between cylinders 1.79 in) in diameter. Otherwise.304 (13. Refer to EC-466. • If the engine speed is out of the specified range check the battery and recharge as necessary. 2. 5. Perform these steps to check each O cylinder.3. Refer to EM-18. "Fuel Pressure Check". COMPRESSION PRESSURE < PERIODIC MAINTENANCE > [QR25DE] COMPRESSION PRESSURE A Compression Pressure INFOID:0000000010709651 CHECKING COMPRESSION PRESSURE EM 1. read the compression pressure and the engine rpm. Remove spark plug from each cylinder. Connect engine tachometer (not required in use of CONSULT. D E F BBIA0534E 4.3. 161) / 250 100 (1. Warm up engine thoroughly. With accelerator pedal fully depressed. L M N SBIA0533E 7. C 3. Install compression tester with an adapter into spark plug hole. "Removal and Installation". 189) / 250 1.0. turn ignition switch to “START” for cranking. When the gauge pointer stabilizes. Check the engine speed again with the battery properly charged. G 6. H I J LBIA0448E K • Use the adapter whose pick up end inserted to spark plug hole is smaller than 20 mm (0. Release fuel pressure. 14) / 250 CAUTION: Always use fully a charged battery to obtain the specified engine speed.108 (11. Compression pressure: Unit: kPa (kg/cm2. Disconnect fuel pump fuse to avoid fuel injection during mea- surement. it may be caught by cylinder head during removal. Revision: August 2014 EM-23 2015 Frontier NAM .

the valves may be malfunctioning. Start engine. 8.If two adjacent cylinders have low compression pressure and their compression remains low even after the addition of engine oil. 10. install removed parts. piston.If the compression pressure remains at a low level despite the addition of engine oil. erase it. cylinder bore. After inspection is completed. Check the piston rings and replace if necessary . "Inspection Procedure". and make sure that engine runs smoothly. piston ring. measure the compression pressure again. If DTC appears. . 9. cylinder head gasket). valve seat.If the added engine oil improves the compression. cylinder head. Replace the valve or valve seat accordingly. Refer to EC-138. After repairing as necessary. COMPRESSION PRESSURE < PERIODIC MAINTENANCE > [QR25DE] • If some cylinders have low compression pressure. . check the valve clearances and parts associ- ated with the combustion chamber (valve. pour a small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. cylinder head gaskets may be leaking. Revision: August 2014 EM-24 2015 Frontier NAM . Perform trouble diagnosis. • If the compression pressure is below the minimum value. piston rings may be worn out or damaged. Check the valves for damage.

INSTALLATION Installation is in the reverse order of removal. O 4. Mass air flow sensor 6. 2. Air duct and resonator assembly 3. Remove mass air flow sensor. AIR CLEANER AND AIR DUCT < REMOVAL AND INSTALLATION > [QR25DE] REMOVAL AND INSTALLATION A AIR CLEANER AND AIR DUCT Exploded View INFOID:0000000010709652 EM C D E F G H I J AWBIA1525ZZ K 1. Air cleaner case 2. Intake manifold assembly 5. 3. • Remove resonator in fender lifting left fender protector. if necessary. Air cleaner filter L Removal and Installation INFOID:0000000010709653 NOTE: M Add mating marks as necessary for easier installation. Disconnect mass air flow sensor harness connector. INSPECTION AFTER REMOVAL Inspect air duct and air duct and resonator assembly for cracks or tears. P 6. Air duct 4. if necessary. as necessary. Remove the air duct and resonator assembly bolts and remove air duct and resonator assembly. Remove the breather hose from the air duct. Loosen the air duct clamps and remove the air duct. 5. Remove air cleaner case. REMOVAL N 1. Revision: August 2014 EM-25 2015 Frontier NAM . • Replace air duct and air duct and resonator assembly.

Tighten clamps firmly. Revision: August 2014 EM-26 2015 Frontier NAM . Attach each joint. AIR CLEANER AND AIR DUCT < REMOVAL AND INSTALLATION > [QR25DE] • Align marks. • Install air duct and resonator assembly to air cleaner case by aligning "LOCK-UNLOCK" upward.

Air duct 23. Water hose 22. Vacuum hose 12. PCV hose 20. Intake manifold 14. 6. To PCV valve N D. Vacuum hose 5. "Fuel Pressure Check". Electric throttle control actuator 24. Mass air flow sensor A. Revision: August 2014 EM-27 2015 Frontier NAM . Collar 9. Gasket M 19. REMOVAL 1. O–ring K EVAP canister purge volume control 4. etc. NOTE: When removing components such as hoses. INTAKE MANIFOLD < REMOVAL AND INSTALLATION > [QR25DE] INTAKE MANIFOLD A Exploded View INFOID:0000000010709654 EM C D E F G H I J AWBIA1012GB 1. Intake manifold support 11. Refer to EC-466. Service port 8. Grommet L 10. To brake booster C. cap or plug openings to prevent fluid from spill- ing. Vacuum hose solenoid valve 7.. Fuel tube protector 15. To heater pipe F. Gasket 13. Air cleaner filter 16. To vacuum pipe (EVAP canister) B. Vacuum hose 2. PCV hose 18. Air cleaner case 17. To rocker cover Engine front O Removal and Installation INFOID:0000000010709655 CAUTION: P Do not remove or disassemble parts unless instructed as shown. To heater outlet E. Water hose 21. Vacuum hose adapter 3. tubes/lines. Release fuel pressure.

NOTE: Disregard No. Remove mass air flow sensor from intake manifold. INTAKE MANIFOLD < REMOVAL AND INSTALLATION > [QR25DE] 2. Remove intake manifold support. air cleaner filter and air duct and resonator assembly. Refer to PG-89. Disconnect water hoses from electric throttle control actuator. Remove quick connector cap. Partially drain engine coolant. and remove intake manifold. CAUTION: Handle the mass air flow sensor with care: • Do not shock it. Remove electric throttle control actuator as follows: a. Refer to EM-39. Remove EVAP canister purge volume control solenoid valve and vacuum hose adapter from intake mani- fold. Remove air cleaner case. CAUTION: • Perform this step when engine is cold. • Do not disassemble it. and disconnect quick connector at the engine side. Loosen bolts in reverse order as shown. vacuum hoses and PCV hoses from intake manifold. "Changing Engine Coolant". • Do not touch the internal sensor. Revision: August 2014 EM-28 2015 Frontier NAM . Disconnect battery negative terminal. PBIC2988E 12. Disconnect harness. • Do not disassemble intake manifold. if necessary. 13. Loosen nuts and bolts in reverse order as shown. 4. PBIC2987E 9. Refer to CO-12. CAUTION: • Handle carefully to avoid any shock to electric throttle control actuator. • Do not spill engine coolant on drive belt. Refer to EM-39. and move them aside. 6 when loosening. "Removal and Installation". Disconnect sub-harness from fuel injector. CAUTION: • Cover engine openings to avoid entry of foreign materi- als. 7. b. 11. LBIA0450E 8. 3. fuel tube protector and gasket. 6. 5. Refer to EM-25. "Exploded View". and remove electric throttle control actuator and gasket. 10. • Do not disassemble. Disconnect harness connector.

if necessary. or any oils/fluids including engine oil and engine coolant. • Bleed air from passages in lines and hoses. • Perform the “Throttle Valve Closed Position Learning” when har- ness connector of electric throttle control actuator is disconnected. check again for fuel leakage at connection points. M NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation.96 kg-m. • Turn ignition switch ON (with engine stopped). again check oil/fluid levels including engine oil and engine coolant. H Refer to EC-123. With engine speed increased. 83 in-lb) C • Tighten in numerical order as shown. slack in the guide may generate a pounding noise during and just after engine start. NOTE: No. Refer to EM-39. 6 E M8 x 35 mm (1. Noise will stop after hydraulic pressure rises. Remove fuel tube and fuel injector assembly from intake manifold. However. • Summary of the inspection items: P Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage Revision: August 2014 EM-29 2015 Frontier NAM . O • After cooling down engine. check for fuel leak. • Run engine to check for unusual noise and vibration. 4. this is normal. 1. L age at connection points.50 in) (Color green) : No. • Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when electric throttle control actuator is replaced. "FOR USA AND CANADA : Fluids and Lubricants" (United States and Canada). Refer to MA-16. check oil/fluid levels including engine coolant and engine oil. If less than required K quantity. I PBIC2987E J INSPECTION AFTER INSTALLATION • Before starting engine. 6 means double tightening of bolt No. fill to the specified level. 1. A INSTALLATION Installation in the reverse order of removal. install them and tighten to the specified torque below. 5 F PBIC2988E Electric Throttle Control Actuator • Tighten bolts equally and diagonally in several steps and in numer. Intake manifold stud : 9. "Throttle Valve Closed Position Learning". Refill to spec- ified level. G ical order as shown. • Start engine.4 N·m (0. N • Warm up engine thoroughly to make sure there is no leakage of fuel. Refer to EC-124. INTAKE MANIFOLD < REMOVAL AND INSTALLATION > [QR25DE] 14. Intake Manifold and Fuel Tube Protector EM • If stud bolts were removed. • Use procedure below to check for fuel leakage. exhaust gas. M8 x 38 mm (1. D Use the following for locating bolts and nuts. 3 Nut : No. "Idle Air Volume Learning". 2. With fuel pressure applied to fuel piping.38 in) : No. such as in cooling system.

Revision: August 2014 EM-30 2015 Frontier NAM . brake fluid. INTAKE MANIFOLD < REMOVAL AND INSTALLATION > [QR25DE] Item Before starting engine Engine running After engine stopped Other oils and fluids* Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas — Leakage — *Power steering fluid. etc.

Air fuel ratio sensor 1 2. Bracket 5.7 in) onto a hard surface such as a concrete floor. O 5. L 2. 3.5 m N (19. Remove exhaust manifold cover. Remove air fuel ratio sensor 1 using Tool. Remove bracket between exhaust manifold–three way catalyst assembly and transmission assembly. EXHAUST MANIFOLD AND THREE WAY CATALYST < REMOVAL AND INSTALLATION > [QR25DE] EXHAUST MANIFOLD AND THREE WAY CATALYST A Exploded View INFOID:0000000010709656 EM C D E F G H I WBIA0647E 1. "Exploded View". Tool number : — (J-44626) M CAUTION: • Be careful not to damage air fuel ratio sensor 1. 4. Exhaust manifold and three way catalyst assembly 3. and harness from bracket and middle clamp. Gasket J 4. Exhaust manifold cover Removal and Installation INFOID:0000000010709657 K REMOVAL 1. • Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0. Refer to EX-5. Disconnect harness connector of air fuel ratio sensor 1. Remove exhaust front tube. P Revision: August 2014 EM-31 2015 Frontier NAM . replace with a new one.

11 ft-lb) 2. PBIC2991E INSTALLATION installation is in the reverse order of removal.7 N·m (1. INSPECTION AFTER REMOVAL Surface Distortion • Check the surface distortion of exhaust manifold and three way catalyst assembly mating surface with straightedge and feeler gauge. clean exhaust system threads using suitable tool and apply anti-seize lubricant. replace exhaust manifold and three way cat- alyst assembly. Tighten nuts in numerical order as shown. Limit : 0. PBIC2990E 7. Remove gasket. 3. CAUTION: Cover engine openings to avoid entry of foreign materials.3 mm (0. • Before installing new air fuel ratio sensor 1. Loosen nuts in reverse order as shown to remove exhaust man- ifold and three way catalyst assembly. Exhaust Manifold 1. install them and tighten to the specified torque. If stud bolts were removed. resulting in the “MIL” coming on. Doing so may cause damage to air fuel ratio sensor 1.012 in) • If it exceeds the limit. Tighten nuts in numerical order as shown again. PBIC2990E Air Fuel Ratio Sensor 1 CAUTION: • Do not over tighten air fuel ratio sensor 1.5 kg-m. Exhaust manifold stud bolt : 14. EXHAUST MANIFOLD AND THREE WAY CATALYST < REMOVAL AND INSTALLATION > [QR25DE] 6. Oxygen sensor thread cleaner : — (J-43897-12) Oxygen sensor thread cleaner : — (J-43897-18) Revision: August 2014 EM-32 2015 Frontier NAM .

Drain engine oil. do not drain engine oil when engine is hot. Remove lower joint shaft pinch bolt at steering gear. Drain plug washer H Removal and Installation INFOID:0000000010709659 I REMOVAL WARNING: To avoid the danger of being scalded. J NOTE: When removing components such as hoses. tubes/lines. "Changing Engine Oil". Loosen bolts in reverse order as shown with power tool. O P PBIC2993E Revision: August 2014 EM-33 2015 Frontier NAM . Oil pan 2. 2. etc. N Remove A/T fluid cooler tube bracket (A/T models). 3. "Removal and Installation". Remove steering gear bolts. K 1. L • Do not spill engine oil on drive belt. Refer to ST-15. "Removal and Installation". M 4.. Drain plug 4. Refer to LU-10. A/T fluid cooler tube bracket (A/T models) 3. OIL PAN < REMOVAL AND INSTALLATION > [QR25DE] OIL PAN A Exploded View INFOID:0000000010709658 EM C D E F G PBIC2992E 1. Remove oil pan with the following procedure: a. CAUTION: • Perform this step when the engine is cold. cap or plug openings to prevent fluid from spill- ing. 5. Remove 3rd crossmember assembly. Refer to ST-12.

NOTE: Tap (1) Tool to insert it and then slide (2) it by tapping on the side of the Tool as shown. WBIA0566E INSPECTION AFTER REMOVAL Clean oil strainer if any object attached. Refer to LU-10. Tool number : KV10111100 (J-37228) CAUTION: • Be careful not to damage the mating surfaces. CAUTION: Attaching should be done within 5 minutes after coating. Use Genuine RTV Silicone Sealant or equivalent. • Also remove the old liquid gasket from mating surface of cylin- der block. "Changing Engine Oil". PBIC2993E 2. Revision: August 2014 EM-34 2015 Frontier NAM . Apply a continuous bead of liquid gasket using a suitable tool as shown. Install oil pan drain plug. Install oil pan with the following procedure: a. this will damage the mating surfaces.1 and 9 as shown (A/T models). PBIC2994E b. PBIC2984E c. NOTE: Pour engine oil at least 30 minutes after oil pan is installed. Use a scraper to remove old liquid gasket from mating surfaces. • Do not insert a screwdriver. INSTALLATION 1. Insert Tool between the oil pan and the cylinder block and remove oil pan. Installation is in the reverse order of removal after this step. • Install A/T fluid cooler tube bracket with bolts No. Refer to GI-21. Tighten bolts in numerical order as shown. CAUTION: Do not scratch or damage the mating surfaces when clean- ing off old liquid gasket. • Remove old liquid gasket from the bolt holes and threads. "Recommended Chemical Products and Sealants". 3. OIL PAN < REMOVAL AND INSTALLATION > [QR25DE] b.

C NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation. If less than required A quantity. brake fluid. check oil/fluid levels including engine coolant and engine oil. Refill to spec- ified level. • Summary of the inspection items: F Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level G Engine oil Level Leakage Level Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage transaxle fluid H M/T Models Level/Leakage Leakage Level/Leakage Other oils and fluids* Level Leakage Level Fuel Leakage Leakage Leakage I Exhaust gas — Leakage — *Power steering fluid. fill to the specified level. • Warm up engine thoroughly to make sure there is no leakage of fuel. • Bleed air from passages in lines and hoses. • Run engine to check for unusual noise and vibration. Noise will stop D after hydraulic pressure rises. exhaust gas. • Use procedure below to check for fuel leakage. again check oil/fluid levels including engine oil and engine coolant. check for fuel leak- age at connection points. With fuel pressure applied to fuel piping. E • After cooling down engine. • Start engine. or any oils/fluids including engine oil and engine coolant. However. this is normal. check again for fuel leakage at connection points. slack in the guide may generate a pounding noise during and just after engine start. etc. if necessary. With engine speed increased. J K L M N O P Revision: August 2014 EM-35 2015 Frontier NAM . EM • Turn ignition switch ON (with engine stopped). "FOR USA AND CANADA : Fluids and Lubricants" (United States and Canada). Refer to MA-16. such as in cooling system. OIL PAN < REMOVAL AND INSTALLATION > [QR25DE] INSPECTION AFTER INSTALLATION • Before starting engine.

3. Rocker cover Removal and Installation INFOID:0000000010709661 REMOVAL 1. Spark plug 3. Ignition coil 2. CAUTION: Do not shock ignition coil. IGNITION COIL < REMOVAL AND INSTALLATION > [QR25DE] IGNITION COIL Exploded View INFOID:0000000010709660 WBIA0648E 1. Disconnect harness connector from ignition coil. Remove intake manifold. 2. Revision: August 2014 EM-36 2015 Frontier NAM . Remove ignition coil. Refer to EM-27. INSTALLATION Installation is in the reverse order of removal.

Disconnect PCV hose from rocker cover. O-ring 4. PCV valve 3. 3. M N O PBIC3003E 7. Refer to EM-36. Refer to EM-27. CAUTION: Do not reuse O-rings. Oil filler cap 5. PCV hose Removal and Installation INFOID:0000000010709663 I REMOVAL 1. Remove rocker cover gasket from rocker cover. Remove PCV valve and O-ring from rocker cover. Remove ignition coils. 5. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. ROCKER COVER < REMOVAL AND INSTALLATION > [QR25DE] ROCKER COVER A Exploded View INFOID:0000000010709662 EM C D E F G WBIA0650E 1. Loosen bolts in reverse order as shown. J 2. K 4. Remove oil filler cap from rocker cover. 1). PCV hose 2. Remove intake manifold. if necessary. Rocker cover 6. INSTALLATION Revision: August 2014 EM-37 2015 Frontier NAM . L 6. P 8. if necessary. Rocker cover gasket H 7. CAUTION: Do not scratch or damage the mating surface when cleaning off old liquid gasket.

Apply liquid gasket to joint part of camshaft bracket (a) (No.2 kg-m. Install rocker cover. 1) as follows: Use Genuine RTV Silicone Sealant or equivalent. Install new rocker cover gasket to rocker cover. Installation of the remaining components is in the reverse order of removal. a. 3. Tighten bolts in two steps in numerical order as shown. Apply liquid gasket (b) 90° to figure (a). ROCKER COVER < REMOVAL AND INSTALLATION > [QR25DE] 1. Apply liquid gasket using a suitable tool to joint of rocker cover. Refer to GI-21.0 N·m (0. 1) and cylinder head. PBIC2635E 2. 1st step : 2. • Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover. 4. cylinder head and camshaft bracket (No.3 N·m (0. b.85 kg-m. Revision: August 2014 EM-38 2015 Frontier NAM . 73 in-lb) PBIC3003E 5. 18 in-lb) 2nd step : 8. "Recommended Chemical Products and Sealants".

FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION > [QR25DE]
FUEL INJECTOR AND FUEL TUBE
A
Exploded View INFOID:0000000010709664

EM

C

D

E

F

G
WBIA0649E

1. Fuel feed hose 2. Quick connector cap (engine side) 3. Sub-harness
4. Fuel tube 5. O-ring (black) 6. Clip
H
7. Fuel injector 8. O-ring (green)

Removal and Installation INFOID:0000000010709665 I

WARNING:
• Put a “CAUTION FLAMMABLE” sign in the workshop. J
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION:
Do not remove or disassemble parts unless instructed. K
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing. L
REMOVAL
1. Release fuel pressure. Refer to EC-466, "Fuel Pressure Check".
M
2. Disconnect the fuel quick connector on the engine side.

N

O

P
LBIA0450E

Revision: August 2014 EM-39 2015 Frontier NAM

FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION > [QR25DE]
a. Remove quick connector cap.

KBIA0701E

b. With the sleeve side of Tool facing quick connector, install Tool
onto fuel tube.

Tool number : — (J-45488)
c. Insert Tool into quick connector until sleeve contacts and goes
no further. Hold the Tool on that position.
CAUTION:
Inserting the Tool hard will not disconnect quick connector.
Hold Tool where it contacts and goes no further.
d. Pull the quick connector out straight from the fuel tube. KBIA0702E
CAUTION:
• Pull quick connector holding it at the (A) position, as shown.
• Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
• Do not reuse O-rings.
• Prepare container and cloth beforehand as fuel will leak out.
• Avoid fire and sparks.
• Do not expose parts to battery electrolyte or other acids.
• Do not bend or twist connection between quick connector and fuel feed hose during removal
and installation.
• Be sure to cover openings of disconnected pipes with
plug or plastic bag to avoid fuel leakage and entry of for-
eign materials.

PBIC2205E

3. Remove intake manifold. Refer to EM-27, "Removal and Installation".
4. Disconnect harness connector from fuel injector.
5. Loosen bolts in reverse order as shown and remove fuel tube
and fuel injector assembly.
CAUTION:
• Be careful to avoid any interference with fuel injector.
• Use a shop cloth to absorb any fuel leaks from fuel tube.

PBIC2998E

Revision: August 2014 EM-40 2015 Frontier NAM

FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION > [QR25DE]
6. Remove fuel injector from fuel tube as follows:
a. Carefully open and remove clip. A
b. Remove fuel injector from fuel tube by pulling straight.
CAUTION:
• Be careful with remaining fuel that may leak out from fuel EM
tube.
• Do not reuse O-rings.
• Do not damage fuel injector nozzles during removal.
C
• Do not bump or drop fuel injectors.
• Do not disassemble fuel injectors.

D

E

F

G
PBIC2999E

INSTALLATION H
1. Install new O-rings to fuel injector, paying attention to the following.
CAUTION:
• Upper and lower O-rings are different colors.
I
Fuel tube side : Black
Nozzle side : Green
J
• Handle O-ring with bare hands. Do not wear gloves.
• Lubricate O-ring with new engine oil.
• Do not reuse O-rings.
K
• Do not clean O-ring with solvent.
• Make sure that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails.
• Do not twist or stretch O-ring. If O-ring was stretched while it was being attached, allow it to L
retract before inserting it into fuel tube.
• Insert new O-ring straight into fuel tube. Do not angle or twist it.
M

N

O

P

Revision: August 2014 EM-41 2015 Frontier NAM

FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION > [QR25DE]
2. Install fuel injector to fuel tube.
a. Insert clip into clip mounting groove on fuel injector.
• Insert new clip so that protrusion of fuel injector matches cut-
out of clip.
CAUTION:
• Do not reuse clip. Replace it with a new one.
• Do not reuse O-rings.
• Do not allow the clip to interfere with the O-ring. If interfer-
ence occurs, replace O-ring.
b. Insert the fuel injector into the fuel tube with the clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion of fuel tube matches cut-
out of clip.
• Make sure that fuel tube flange is securely fixed in flange fixing
groove on clip.
c. Make sure that installation is complete by checking that the fuel
injector does not rotate or come off.
• Make sure that protrusions of the fuel injectors are aligned
with cutouts of clips after installation.

PBIC3000E

3. Install fuel tube and fuel injector assembly as follows:
CAUTION:
Do not let the tip of the injector nozzle come in contact with other parts.
a. Insert the tip of each fuel injector into intake manifold.
b. Tighten bolts in two steps in numerical order as shown.

Fuel tube bolts
1st step : 12.8 N·m (1.3 kg-m, 9 ft-lb)
2nd step : 28.0 N·m (2.9 kg-m, 21 ft-lb)

PBIC2998E

4. Connect harness connectors to fuel injectors.
5. Install intake manifold. Refer to EM-27, "Removal and Installation".
6. Connect quick connector at the engine side as follows:
a. Check the connection for foreign material and damage.
b. Align center to insert quick connector straight into fuel tube.
NOTE:
The figure shows the engine side as an example.
• Insert quick connector to fuel tube until the top spool on fuel
tube is inserted completely and the second level spool is posi-
tioned slightly below quick connector bottom end.
CAUTION:
• Hold (A) position as shown when inserting fuel tube into
quick connector.
• Do not reuse O-rings.
• Carefully align center to avoid inclined insertion to pre-
KBIA0272E
vent damage to O-ring inside quick connector.
• Insert until you hear a “click” sound and actually feel the engagement.
• To avoid misidentification of engagement with a similar sound, be sure to perform the next
step.

Revision: August 2014 EM-42 2015 Frontier NAM

FUEL INJECTOR AND FUEL TUBE
< REMOVAL AND INSTALLATION > [QR25DE]
c. Before clamping fuel feed hose with quick connector cap, pull quick connector hard by hand holding (A)
position. Make sure it is completely engaged (connected) so that it does not come out from fuel feed tube. A
d. Install quick connector cap to quick connector connection.
(engine side)
• Install so that the arrow mark on the side faces up. EM
CAUTION:
• Make sure that quick connector and fuel tube are securely
fit into quick connector cap installation groove.
• If quick connector cap cannot be installed smoothly, C
quick connector may have not been installed correctly.
Check the connection again.
7. Install fuel feed hose to hose clamp. D
8. Installation is in the reverse order of removal after this step. PBIC2348E

INSPECTION AFTER INSTALLATION
E
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-16, "FOR USA AND CANADA : Fluids and Lubricants" (United
States and Canada).
• Use procedure below to check for fuel leakage. F
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
• Start engine. With engine speed increased, check again for fuel leakage at connection points. G
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop H
after hydraulic pressure rises.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant. I
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec-
ified level, if necessary.
• Summary of the inspection items: J

Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level K
Engine oil Level Leakage Level

Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage
L
transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage M
Exhaust gas — Leakage —
*Power steering fluid, brake fluid, etc.
N

O

P

Revision: August 2014 EM-43 2015 Frontier NAM

Revision: August 2014 EM-44 2015 Frontier NAM . CAUTION: Do not reuse O-ring. Disconnect harness connector from intake valve timing control solenoid valve. AWBIA1007GB INSTALLATION Installation is in the reverse order of removal. Remove intake valve timing control solenoid valve bolt. 3. 2. • Lubricate the new O-ring for the intake valve timing control solenoid valve with clean engine oil before installing. INTAKE VALVE TIMING CONTROL < REMOVAL AND INSTALLATION > [QR25DE] INTAKE VALVE TIMING CONTROL Intake Valve Timing Control Solenoid Valve INFOID:0000000010709666 REMOVAL 1. Remove intake valve timing control solenoid valve (1) and O-ring (2) from intake valve timing control sole- noid valve cover. CAUTION: • Do not reuse O-rings.

Chain tensioner plunger 7. Timing chain 9. Refer to EM-46. Intake valve timing control cover valve 13. Timing chain tension guide 21. Balancer unit sprocket 23. Balancer unit 22. TIMING CHAIN < REMOVAL AND INSTALLATION > [QR25DE] TIMING CHAIN A Exploded View INFOID:0000000010709667 EM C D E F G H I J K L M WBIA0834E N 1. Timing chain slack guide 8. Spacer 19. Crankshaft pulley P 16. Crankshaft sprocket 18. Camshaft sprocket (EXH) 4. "Removal and Instal- lation" Revision: August 2014 EM-45 2015 Frontier NAM . Oil ring 14. Chain guide 11. Front oil seal 15. 12. Refer to EM-46. O-ring 2. Camshaft sprocket (INT) 3. Crankshaft pulley bolt 17. Front cover O Intake valve timing control solenoid 10. Balancer unit timing chain A. Chain tensioner 5. Spring 6. "Removal and Instal- lation" B. Balancer unit timing chain tensioner 20.

Refer to EM-33. Refer to EC-466. Remove the drive belt auto-tensioner. Rotate the crankshaft pulley clockwise and align the mating marks to the timing indicator on the front cover. KBIA0115E Revision: August 2014 EM-46 2015 Frontier NAM . Remove the air cleaner case and air duct and resonator assembly. KBIA0190E b. 11. 7. "Removal and Installation of Drive Belt Auto-Ten- sioner". Remove the oil pan. Refer to EM-18. rotate the crankshaft pulley one more turn to line up the mating marks to the positions as shown. Remove intake valve timing control cover bolts in the order as shown. Dismount and position aside the power steering pump and reservoir tank with the piping attached. 8. "Removal and Installation". 5. Refer to EM-37. 4. 12. 10. Pull chain guide between camshaft sprockets out through front cover. 9. "Removal and Instal- lation". Refer to FSU-13. At the same time. Remove the generator. "Removal and Installation". and oil strainer. 3. "Fuel Pressure Check". • If not lined up. "Component". KBIA0085E 15. Refer to EM-15. 6.QR25DE Models". Remove the intake valve timing control cover by cutting the seal- ant using Tool. Remove the spark plugs. Remove the coolant overflow reservoir tank. Dismount and position aside the A/C compressor with the piping attached.1 cylinder at TDC on the compression stroke with the following procedure: a. TIMING CHAIN < REMOVAL AND INSTALLATION > [QR25DE] Removal and Installation INFOID:0000000010709668 REMOVAL 1. Tool number : KV10111100 (J-37228) 14. 13. Set the No. make sure that the mating marks on the cam- shaft sprockets are lined up as shown. Remove the strut tower brace. "Removal and Installation . Release the fuel pressure. Refer to EM-25. Refer to CHG-28. 2. "Removal and Installation". Remove the rocker cover.

CAUTION: M Be careful not to damage the mating surface.24 in diameter) thread hole on crankshaft pulley. Attach a pulley puller in the M6 (0.39 in). Remove the front cover as follows: a. and L remove them. and pull the pulley out about 10 mm (0. If the front oil seal needs to be replaced. Remove the front cover. remove it using a suit. C KBIA0077E D b. TIMING CHAIN < REMOVAL AND INSTALLATION > [QR25DE] 16. Loosen the front cover bolts in the reverse order as shown. I J SEM829E K 18. CAUTION: EM Do not remove the crank shaft pulley bolt as it will be used as a supporting point for the Tool. then loosen the A crankshaft pulley bolt. b. Hold the crankshaft pulley with a suitable tool. Remove crankshaft pulley with the following procedure: a. and remove crankshaft pulley. N O P KBIA0083E Revision: August 2014 EM-47 2015 Frontier NAM . E F G KBIA0078E 17. H able tool.

Secure the hexagonal portion of the balancer shaft using a suitable tool. Remove balancer unit timing chain tensioner with the following procedure: a. insert a stopper pin to secure tensioner sleeve. Refer to EM-54.5 mm (0. Push tensioner sleeve in. NOTE: Use socket (size E14) for bolts No. 24. Loosen the balancer unit sprocket bolt. 25. Remove balancer unit timing chain. and remove balancer unit. PBIC3027E 23. Remove balancer unit timing chain tensioner. Remove timing chain slack guide. It causes interference between valve and piston. Lift lever up. PBIC3028E INSPECTION AFTER REMOVAL Timing Chain Revision: August 2014 EM-48 2015 Frontier NAM . CAUTION: Do not disassemble balancer unit. c. timing chain tension guide and spacer. Insert a stopper pin into hole on chain tensioner body to secure chain tensioner plunger and remove chain tensioner. hard metal pin as a stopper pin. and hold it. and release ratchet claw for return proof. NOTE: When removing balancer unit timing chain. 21. CAUTION: Do not rotate crankshaft or camshaft while timing chain is removed. NOTE: Use approximately 1 mm (0.04 in) dia. NOTE: Use approximately 0. b. TIMING CHAIN < REMOVAL AND INSTALLATION > [QR25DE] 19. Matching the hole on lever with the one on body. Remove timing chain. d.02 in) dia. Remove timing chain with the following procedure: a. KBIA0048E b. 20. Remove camshaft sprockets. Loosen bolts in reverse order as shown. 22. balancer unit sprocket and crankshaft sprocket. remove crankshaft sprocket and balancer unit sprocket at the same time. Push in chain tensioner plunger.1 to 4. hard metal pin as a stop- per pin.

77 in) I INSTALLATION NOTE: The figure shows the relationship between the mating mark on each J timing chain and that on the corresponding sprocket. TIMING CHAIN < REMOVAL AND INSTALLATION > [QR25DE] Check timing chain for cracks and any excessive wear at the roller links of timing chain.15 mm (0. Revision: August 2014 EM-49 2015 Frontier NAM . replace balancer unit bolt with a new one. Install O-ring to balancer unit. (d2)] at two positions as shown. Replace timing chain if necessary. E Limit [(d1) – (d2)] : 0.0059 in) • If it exceeds the limit (large difference in dimensions). Make sure that crankshaft key points straight up. F G PBIC1137E Balancer Unit Bolt Length H Measure balancer unit bolt length. 1. K L M N O P PBIC3029E 2. If it exceeds the limit. CAUTION: Do not reuse O-ring. • If reduction appears in (A) range. regard it as (d2). replace bal- ancer unit bolt with a new one. Limit : 172 mm (6. A EM C PBIC0282E D Balancer Unit Bolt Outer Diameter • Measure outer diameters [(d1). with the com- ponents installed.

1 N·m (4. Install crankshaft sprocket. PBIC3032E Revision: August 2014 EM-50 2015 Frontier NAM .1 kg-m. Tool number : KV10112100 (BT8653-A) CAUTION: If bolts are re-used. 0 ft-lb) Step 4 bolts 1 . 22 ft-lb) PBIC3030E 4. Do not make judgment by visual check alone. using Tool. Tighten bolts in numerical order as shown with the following pro- cedure to install balancer unit. Follow the "Balancer Unit Bolt Outer Diameter" pro- cedure.4 : 100° clockwise Step 3 bolts 1 .1 N·m (3. CAUTION: • Check tightening angle using Tool or a protractor. • After installation.9 kg-m.1 N·m (4. Install balancer unit timing chain tensioner. NOTE: PBIC2183E Install crankshaft sprocket. make sure the mating marks have not slipped. NOTE: Apply new engine oil to threads and seat surfaces of bolts. 5. balancer unit sprocket and balancer unit timing chain. then remove stopper pin and release tensioner sleeve. 35 ft-lb) Step 2 bolts 1 . check their outer diameter before instal- lation.6 : 30.4 : 48. • Make sure that crankshaft sprocket is positioned with mating marks on cylinder block and crankshaft sprocket meeting at the top. • Install it by aligning mating marks on each sprocket and bal- ancer unit timing chain. TIMING CHAIN < REMOVAL AND INSTALLATION > [QR25DE] 3. loosen bolts in reverse order as shown. 35 ft-lb) Step 5 bolts 1 . PBIC3028E • In step 3.9 kg-m. Tighten the balancer unit sprocket bolt to the specified torque.4 : 48. Balancer bolt torque Step 1 bolts 1 .4 : 100° clockwise Step 6 bolts 5 . balancer unit sprocket and balancer unit timing chain at the same time.4 : 0 N·m (0 kg-m. • Secure the hexagonal portion of the balancer shaft using a suitable tool.

H 8.177 . D NOTE: Before installing chain tensioner. using a suitable tool. remove stopper pin.0.) Detail of C : Between here only. Then install front cover. apply 4. Revision: August 2014 EM-51 2015 Frontier NAM . • Before and after installing chain tensioner. keep them aligned by holding them with a hand.217 in) dia. • Install by aligning mating marks on each sprocket and timing A chain. Install timing chain and related parts. N O PBIC3031E 10. Apply a continuous bead of liquid gasket with the tube presser I to front cover as shown. Refer to GI-21. P CAUTION: Be careful not to damage front oil seal by interference with front end of crankshaft. EM • After installing chain tensioner. Use Genuine RTV Silicone Sealant or equivalent. J NOTE: Application instruction differs depending on the position. do not rotate crankshaft and camshaft until front cover is installed. CAUTION: Do not reuse O-rings. 9. TIMING CHAIN < REMOVAL AND INSTALLATION > [QR25DE] 6. CAUTION: • For the following note. • To avoid skipped teeth. Make sure that mating marks of timing chain and each sprocket are still aligned. it is possible to change the position of mating mark on timing chain for that on each sprocket for alignment. apply to the inside. and make sure that tensioner moves freely.5. K Detail of A : Cross over the start of the applica- tion and the end. (For all bolt holes other than B. Install O-rings to cylinder head and cylinder block.5 M mm (0. E F G PBIC3029E 7. Detail of B : Apply liquid gasket outside of bolt L holes. "Removal and Installation of Front Oil Seal". after the mating marks are C aligned. Refer to EM-63. "Recommended Chemical Products and Sealants". Install front oil seal to front cover.5 . check again to make sure that mating marks have not slipped.

0 N·m (5. CAUTION: Do not reuse O-ring. 14. 14. 17 : 45 mm (1. Tighten bolts in numerical order as shown.77 in) Except the above (Except : 20 mm (0. "Recommended Chemical Products and Sealants". Insert crankshaft pulley by aligning with crankshaft key. and install harness clip. Use Genuine RTV Silicone Sealant or equivalent. 19. 10.0 kg-m.8 N·m (1. KBIA0083E 13. Connect ground cables. SBIA0260E 17. 9 ft-lb) 1 through 4 : 49. Tighten bolts in numerical order as shown. retighten them to the specified torque in numerical order as shown. After all bolts are tightened. 36 ft-lb) 12. Apply a continuous bead of liquid gasket using a suitable tool to intake valve timing control cover as shown. Install intake valve timing control solenoid valve to intake valve timing control cover if removed. Revision: August 2014 EM-52 2015 Frontier NAM . 16.79 in) 1 through 4) • Tighten bolts to the specified torque.3 kg-m. 20. Install chain guide between camshaft sprockets. • Use the following for locating M6 bolts. Install O-rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control cover. 15. Refer to GI-21. CAUTION: Do not reuse O-ring. CAUTION: Be sure to wipe off any excessive liquid gasket leaking to surface for fitting oil pan. Bolt position Bolt length 5. KBIA0085E 18. TIMING CHAIN < REMOVAL AND INSTALLATION > [QR25DE] 11. Install O-ring to front cover. Bolt position Torque specification 5 through 17 : 12.

TIMING CHAIN < REMOVAL AND INSTALLATION > [QR25DE] • When inserting crankshaft pulley with a plastic hammer. 21. b. Refer to MA-16. fill to the specified level. Turn another 60° degrees clockwise (angle tightening). exhaust gas. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. "FOR USA AND CANADA : Fluids and Lubricants" (United States and Canada). mating with any one of six easy to recognize angle marks on bolt flange. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation. • Summary of the inspection items: M Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level N Engine oil Level Leakage Level Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage O transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage Other oils and fluids* Level Leakage Level Fuel Leakage Leakage Leakage P Exhaust gas — Leakage — *Power steering fluid. • Use procedure below to check for fuel leakage. • Secure crankshaft pulley using suitable tool. such as in cooling system. this is normal. Installation is in the reverse order of removal. • Check the tightening angle with movement of one angle mark. If less than required quantity. tap on its center portion (not circumference). check for fuel leak- age at connection points. I • Turn ignition switch ON (with engine stopped). • After cooling down engine. • Warm up engine thoroughly to make sure there is no leakage of fuel. D d. brake fluid. With engine speed increased. With fuel pressure applied to fuel piping.3 kg-m. Tighten crankshaft pulley bolt. Revision: August 2014 EM-53 2015 Frontier NAM . if necessary. check again for fuel leakage at connection points. slack in the guide may generate a pounding noise during and just after engine start. or any oils/fluids including engine oil and engine coolant. CAUTION: A Do not damage front oil seal lip section. Tighten crankshaft pulley bolt.1 N·m (4. E F SEM751G G 22. Noise will stop K after hydraulic pressure rises. EM a. check oil/fluid levels including engine coolant and engine oil. and tighten crankshaft pulley bolt. C Crankshaft pulley bolt : 42. 31 ft-lb) c. J • Run engine to check for unusual noise and vibration. again check oil/fluid levels including engine oil and engine coolant. • Start engine. However. Refill to spec- ified level. etc. L • Bleed air from passages in lines and hoses. INSPECTION AFTER INSTALLATION H • Before starting engine. Put a paint mark on crankshaft pulley.

Seal washer 3. Camshaft position sensor (PHASE) A. Camshaft (EXH) 20. Intake valve timing control cover 14. Chain tensioner plunger 9. When neces- sary remove the front cover. Oil ring 11. Camshaft bracket (No. CAMSHAFT < REMOVAL AND INSTALLATION > [QR25DE] CAMSHAFT Exploded View INFOID:0000000010709669 WBIA0833E 1. Disconnect and remove the camshaft position sensor (PHASE). 4. 1) 4. Disconnect the harness connector from the intake valve timing control solenoid. Disconnect the ground harness connectors from the front cover. O-ring 17. valve 13. REMOVAL 1. Camshaft sprocket (INT) 15. Refer to EM-37. "Removal and Installation". Refer to EM-46. 2. "Removal and Installation" Removal and Installation INFOID:0000000010709670 NOTE: This section describes removal/installation procedure of camshaft without removing front cover. Chain guide 6. Spring 8. Refer to EM-54. O-ring Intake valve timing control solenoid 10. Camshaft sprocket (EXH) 16. 5. 2 to 5) 2. Remove the rocker cover. Remove the drive belt. "Removal and Installation". Camshaft bracket (No. installation is in the reverse order of removal. Revision: August 2014 EM-54 2015 Frontier NAM . Chain tensioner 7. Camshaft (INT) 19. Front cover 5. Valve lifter 18. 3. O-ring 12. Refer to EM-14. O-ring 21.

O • Use a wire with 0. N 11. A 7.1 cylinder at TDC on its compression stroke as fol- lows: a. Remove the intake valve timing control cover by cutting the seal- ant using Tool. Line up the mating marks on camshaft sprockets with the yellow links in the timing chain. CAMSHAFT < REMOVAL AND INSTALLATION > [QR25DE] 6. as shown. Rotate crankshaft pulley clockwise. • If not. M NOTE: Maintaining chain tension is not necessary. Remove the timing chain tensioner. Make sure that the mating marks on camshaft sprockets are H lined up with the yellow links in the timing chain. Remove intake valve timing control cover bolts in the order as shown. Push in the tensioner plunger and hold. CAUTION: Do not rotate the crankshaft or camshaft while the timing chain is removed. Pull the timing chain guide out between the camshaft sprockets through front cover. Set the No. and paint an L indelible mating mark on the sprocket and timing chain link plate. CAUTION: EM Be careful not to damage mating surface. and align mating marks for E TDC with timing indicator on front cover. as shown. It causes interference between valve and piston. P KBIA0048E Revision: August 2014 EM-55 2015 Frontier NAM . Tool number : KV10111100 (J-37228) C KBIA0085E D 8. I J KBIA0115E K 9. F G KBIA0190E b. Crankshaft sprocket and timing chain do not disconnect struc- turally while front cover is attached.5 mm (0.02 in) diameter for a stopper pin. Insert a stopper pin into the hole on tensioner body to hold the chain tensioner. 10. rotate crankshaft pulley one more turn to line up the mating marks to the yellow links. as shown.

1. • Note positions.45.975 . If wear is beyond the limit.165 mm (1. 14. Loosen the camshaft bracket bolts in the order as shown. replace camshaft. 2 and 5 jour- nals of camshaft. 3 journal.7797 in) Exhaust : 43.1. and remove the camshaft brackets and camshafts. Secure the camshaft using a suitable tool as shown. replace camshaft.1 camshaft bracket by slightly tapping it with a rubber mallet. and set them aside in the order removed.7388 in) Cam wear limit : 0.008 in) 2. Measure the camshaft cam height with a micrometer. 3. Put V-block on a precise flat table. • Note positions. Loosen the camshaft sprocket bolts and remove the camshaft sprockets. WBIA0028E INSPECTION AFTER REMOVAL Camshaft Runout 1. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations. and set them aside in the order removed. CAMSHAFT < REMOVAL AND INSTALLATION > [QR25DE] 12.0008 in).2 mm (0. Remove the valve lifters.205 mm (1. PBIC2499E 4. Camshaft Cam Height 1. 2.015 . Turn camshaft to one direction with hands.7722 . Set a dial indicator vertically to No. If out of the standard. and measure the camshaft runout on the dial indicator. Standard: Intake : 45. PBIC0039E Camshaft Journal Oil Clearance CAMSHAFT JOURNAL DIAMETER Revision: August 2014 EM-56 2015 Frontier NAM .44. (Total indicator reading) Standard: Less than 0.02 mm (0. KBIA0049E 13.7313 . and support No. CAUTION: Do not support No. • Remove No.

1 : 28. A Standard: No.086 mm (0.955 mm (1.0074 in) N O PBIC2446E P Revision: August 2014 EM-57 2015 Frontier NAM . 4. 2.045 . 3.28.935 .500 .435 .1006 in) No. Install camshaft in cylinder head.0034 in) J • If out of the standard. 5 : 23.000 . E Standard: No.521 mm (0.9234 in) EM C PBIC0040E D CAMSHAFT BRACKET INNER DIAMETER • Tighten camshaft bracket bolts with the specified torque. 1 : 27. M Standard : 0.9252 .188 mm (0.115 .23. Install a dial indicator in thrust direction on front end of camshaft. 3.27. NOTE: Camshaft brackets cannot be replaced as single parts. Refer to EM-54. replace either or both camshaft and cylinder head.0045 . because they are machined together with cylinder K head.0998 . Measure the camshaft end play on the dial indicator when cam- shaft is moved forward/backward (in direction to axis). Camshaft End Play 1.0. L 2. "Removal and Installation".0. • Measure inner diameter “A” of camshaft bracket with a bore gauge.1032 in) F No. 5 : 23.1024 .9226 .0.021 mm (1.9260 in) G PBIC1645E H CAMSHAFT JOURNAL OIL CLEARANCE I • (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter) Standard : 0.0.0018 . Replace whole cylinder head assembly.1. CAMSHAFT < REMOVAL AND INSTALLATION > [QR25DE] Measure the outer diameter of camshaft journal with a micrometer.455 mm (0. 4.0.0. Refer to EM-54. 2. "Removal and Installation".1.23.

33. Measure the camshaft sprocket runout with a dial indicator. 2.848 mm (1.0102 . . replace valve lifter. CAMSHAFT < REMOVAL AND INSTALLATION > [QR25DE] • Measure the following parts if out of the standard.3378 in) JEM798G VALVE LIFTER HOLE DIAMETER Revision: August 2014 EM-58 2015 Frontier NAM .3372 . and then replace camshaft and/or cylinder head. and support No.0157 . "Standard and Limit".0176 in) .0059 in) • If it exceeds the limit.660 . (Total indicator reading) Limit : 0.1.800 .Dimension “B” for cylinder head No. PBIC0930E Valve Lifter Check if surface of valve lifter has any wear or cracks. CAUTION: Do not support No.685 mm (1.Dimension “A” for camshaft No.980 mm (1.1.1. replace camshaft sprocket.25. 1 journal bearing Standard : 25. Refer to EM-108. • If anything above is found. 2 and 5 journals of camshaft. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.25. KBIA0182E Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER • Measure the outer diameter of valve lifter with a micrometer. Standard : 33.15 mm (0. if necessary.0112 in) • Use the standards above. KBIA2426J Camshaft Sprocket Runout 1. Put V-block on precise flat table. 1 journal Standard : 25.965 .

F INSTALLATION 1.0022 in) • If out of the standard.1.000 . Install valve lifters.020 . Remove foreign material completely from camshaft bracket backside and from cylinder head installation O face.056 mm (0.34.0008 . replace either or both valve lifter and cylinder head. • Install them in the original positions.0. A Standard : 34. referring to the standard of valve lifter outer diameter and valve lifter hole diameter. H Intake : Signal plate shape for camshaft posi- tion sensor (PHASE) I Exhaust : Cone end shape J KBIA0246E • Install camshafts so that camshaft dowel pins on the front side K are positioned as shown. L M N KBIA0051E 3. G 2.0.021 mm (1. • Distinction between intake and exhaust camshafts is per- formed with the different shapes of rear end. Install camshaft brackets with the following procedure: a.3386 . Install camshafts. P Revision: August 2014 EM-59 2015 Frontier NAM .3394 in) EM C PBIC0043E D VALVE LIFTER CLEARANCE • (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter) E Standard : 0. CAMSHAFT < REMOVAL AND INSTALLATION > [QR25DE] Measure the diameter of valve lifter hole of cylinder head with an inside micrometer.

Revision: August 2014 EM-60 2015 Frontier NAM . NOTE: Install so that identification mark can be correctly read when viewed from the exhaust side. Install camshaft brackets (No. Apply liquid gasket to camshaft bracket (No. Tighten bolts of camshaft brackets in the following steps. 1) with the following procedure: i. Locate camshaft bracket (No. 2 to 5) aligning the identification marks on upper surface as shown. in numerical order as shown. CAMSHAFT < REMOVAL AND INSTALLATION > [QR25DE] b. 1) near installation position. CAUTION: After installation. and install it without disturbing the liquid gasket applied to the sur- faces. 1) as shown. "Recommended Chemical Products and Sealants". "Recommended Chemical Products and Sealants". Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-21. PBIC2746E 4. Refer to GI-21. Install camshaft bracket (No. • Apply liquid gasket to the outside of bolt hole on front cover. Apply liquid gasket to camshaft bracket (No. be sure to wipe off any excessive liquid gasket leaking from part (A). SBIA0258E iii. 1) contact surface on the front cover backside. Use Genuine RTV Silicone Sealant or equivalent. SBIA0256E c. PBIC2579E ii.

G PBIC2351E 7. D • Install them by aligning the mating marks on each camshaft sprocket with the paint marks on the timing chain link plates during removal. Refer to GI-21. NOTE: Before installation of chain tensioner. CAMSHAFT < REMOVAL AND INSTALLATION > [QR25DE] Step 1 (bolts 9 .9 N·m (0. O P KBIA0085E Revision: August 2014 EM-61 2015 Frontier NAM .11) : 5.2 kg-m. K 11. Install camshaft sprockets. "Recommended Chemical Products and Sealants".0 N·m (0. 8 ft-lb) CAUTION: After tightening bolts of camshaft brackets. be sure to wipe off C excessive liquid gasket from the parts. pull the stopper pin off completely. • Before and after installing chain tensioner. 5. Install chain tensioner. Install chain guide. L M N SBIA0260E 12.4 N·m (1. Install O-rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control I cover.11) : 10. after match- ing them. it is possible to re-match the marks on timing chain with the ones on each sprocket. CAUTION: Do not reuse O-ring. SBIA0255E 6. CAUTION: After installation.2 kg-m.11) : 2. and make sure that chain tensioner plunger H is released. Apply liquid gasket using a suitable tool to intake valve timing control cover as shown. make sure F again that mating marks have not slipped. Install O-ring to front cover. hold the timing chain in place by hand. 9.0 N·m (0. CAUTION: Do not reuse O-rings. 18 in-lb) A Step 2 (bolts 1 .6 kg-m.1 kg-m. Therefore. J 10. Install camshaft position sensor (PHASE). Tighten bolts in numerical order as shown.8) : 2. 18 in-lb) Step 3 (bolts 1 . CAUTION: E • Aligned mating marks could slip. 52 in-lb) EM Step 4 (bolts 1 . 8. Use Genuine RTV Silicone Sealant or equivalent.

Install intake valve timing control solenoid valve to intake valve timing control cover if removed. a. 16.). Refer to LU-9. Revision: August 2014 EM-62 2015 Frontier NAM . "Lubrication Circuit". Do not allow engine oil to get on rubber components such as PBIC2723E drive belt or engine mount insulators. Remove intake valve timing control solenoid valve. Refer toEM-108. Disconnect harness connectors from ignition coil and injector. Use a shop cloth to protect the engine components and the vehicle. Refer to EC-154. "Lubrication Circuit". Connect ground cables. Check and adjust valve clearance. Noise will stop after hydraulic pressure rises. Refer to LU-7. "Fuel Pressure Check". "Removal and Installation". and then make sure that engine oil comes out from intake valve timing control cover oil hole. and then check each oil groove for clogging. 5. • Clean oil groove if necessary. slack in the guide may generate a pounding noise during and just after the engine start. "Inspection". c. 14. Refer to EM-14. Crank the engine. "Component Inspec- tion". Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT). Refer to LU-7. "Standard and Limit". and install harness clip. Immediately wipe off any splashed engine oil. 4. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation. Remove drive belt. 3. Installation is in the reverse order of removal after this step. Installation is in the reverse order of removal. b. 15. idler pul- ley. • Check when the engine is cold so as to prevent burns from any splashing engine oil. and crankshaft pulley. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. However. 2. CAMSHAFT < REMOVAL AND INSTALLATION > [QR25DE] 13. INSPECTION AFTER INSTALLATION Inspection of Camshaft Sprocket (INT) Oil Groove CAUTION: • Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT and it is directed according to inspection procedure of EC section. this is normal. etc. Stop cranking after checking. 1. Check the engine oil level. • Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not come out from intake valve timing control cover oil hole. "Exploded View". WARNING: Be careful not to touch rotating parts (drive belt. Refer to EC-466. CAUTION: Engine oil may squirt from intake valve timing control sole- noid valve installation hole during cranking. Release fuel pressure. Refer to EM-45. 6.

Remove camshaft relating to valve oil seal to be removed. 6. be careful not to damage valve lifter holes. Refer to CO-16. OIL SEAL < REMOVAL AND INSTALLATION > [QR25DE] OIL SEAL A Removal and Installation of Valve Oil Seal INFOID:0000000010709671 REMOVAL EM 1. D 5. Refer to EM-54. 3. Refer to EM-54. Revision: August 2014 EM-63 2015 Frontier NAM . Apply new engine oil to valve oil seal joint surface and seal lip. Remove valve collet. "Exploded View" 2. Remove valve oil seal using Tool. Remove valve lifters. Tool numbers : KV10115600 (J-38958) M N O WBIA0653E 3. Refer to EM-14. Remove drive belt. 4. "Exploded View". This will prevent valve from dropping into cylinder. Refer to CO-19. Remove fan shroud (lower). E • Do not remove valve spring seat from valve spring. Installation of the remaining components is in the reverse order of removal. C 3. Remove fan shroud (lower). Refer to CO-16. Remove valve collet with WBIA0477E magnetic hand. Remove cooling fan. "Removal and Installation". L 2. H Tool numbers : KV10107902 (J-38959) I J WBIA0478E K INSTALLATION 1. CAUTION: • When working. "Removal and Installation (Crankshaft driven type)". Tool numbers : KV10116200 (J-26336-A) F : KV10115900 (J-26336-20) : KV10109220 ( — ) G • Compress valve spring using Tool. 2. P Removal and Installation of Front Oil Seal INFOID:0000000010709672 REMOVAL 1. Press in valve oil seal to the height (H) as shown using Tool. valve spring retainer and valve spring using Tool. Turn crankshaft until the cylinder requiring new oil seals is at TDC.

Install front oil seal. SEM829E INSTALLATION 1. and pull the pulley out about 10 mm (0. OIL SEAL < REMOVAL AND INSTALLATION > [QR25DE] 4. Remove crankshaft pulley with the following procedure: a. KBIA0077E b. 2. • Install front oil seal so that each seal lip is oriented as shown. Attach a pulley puller in the M6 (0. and remove crankshaft pulley.24 in diameter) thread hole on crankshaft pulley. then loosen the crankshaft pulley bolt. CAUTION: Do not remove the crankshaft pulley bolt as it will be used as a supporting point for the Tool. SEM715A Revision: August 2014 EM-64 2015 Frontier NAM . Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal. KBIA0078E 5. CAUTION: Be careful not to damage front cover and crankshaft. Remove front oil seal using a suitable tool. Hold the crankshaft pulley with a suitable tool.39 in).

• Secure crankshaft pulley using suitable tool. Remove drive plate (A/T models) or flywheel (M/T models) with power tool. Tighten crankshaft pulley bolt. OIL SEAL < REMOVAL AND INSTALLATION > [QR25DE] • Press-fit front oil seal until it is flush with front end surface of front cover using suitable tool. Remove rear oil seal with a suitable tool. "Exploded View". "5M/T : Removal and Installation". • Press-fit straight and avoid causing burrs or tilting oil EM seal. N INSTALLATION 1. Crankshaft pulley bolt : 42. 31 ft-lb) F c. Tighten crankshaft pulley bolt. Remove transmission assembly. Turn another 60° degrees clockwise (angle tightening). Remove clutch cover and clutch disk (M/T models). and tighten crankshaft pulley bolt. a. Refer to CL-19. Install rear oil seal so that each seal lip is oriented as shown. A CAUTION: • Be careful not to damage front cover and crankshaft. mating with any one of six easy to recognize angle marks on bolt flange. "Removal and Installation for QR25DE" (A/T models). Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. 2. E b. "Removal and Installation from Vehicle" (M/T models). Apply new engine oil to new rear oil seal joint surface and seal lip. CAUTION: Be careful not to damage crankshaft and cylinder block. TM-306. M 4. G • Check the tightening angle with movement of one angle mark. Refer to TM-21. 3. C PBIC3033E D 3. d. H I SEM751G 4.1 N·m (4. Refer to EM-80. J Removal and Installation of Rear Oil Seal INFOID:0000000010709673 K REMOVAL 1. O P SEM715A Revision: August 2014 EM-65 2015 Frontier NAM . Put a paint mark on crankshaft pulley.3 kg-m. L 2. Installation is in the reverse order of removal after this step.

[outside diameter 102 mm (4. WBIA0654E 3. inside diameter 86 mm (3. • Improper alignment caused by missing dowels may cause vibration. • Press-fit oil seal straight to avoid causing burrs or tilt- ing. Revision: August 2014 EM-66 2015 Frontier NAM . CAUTION: • When replacing an engine or transmission you must make sure the dowels are installed cor- rectly during reassembly.02 in). Installation of the remaining components is in the reverse order of removal. SBIA0280E • Press in rear oil seal to the position as shown. oil leaks or breakage of drivetrain components.39 in)]. CAUTION: • Be careful not to damage crankshaft and cylinder block. OIL SEAL < REMOVAL AND INSTALLATION > [QR25DE] • Install new rear oil seal using suitable tool. • Do not touch grease applied onto oil seal lip.

Refer to EC-466. N 6. etc. 4. "Fuel Pressure Check". L 3. Remove water outlet. Refer to CO-12. 8. Remove front cover and timing chain. K CAUTION: • Perform this step when the engine is cold. Release fuel pressure. "Changing Engine Coolant". Remove fuel injector and fuel tube assembly. Refer to EM-39. Revision: August 2014 EM-67 2015 Frontier NAM . P 10. CYLINDER HEAD < REMOVAL AND INSTALLATION > [QR25DE] CYLINDER HEAD A Exploded View INFOID:0000000010709674 EM C D E F G WBIA0835E 1. 5. Cylinder head bolt A. Refer to EM-67. Cylinder head gasket 3. "Exploded View". Refer to LU-10. Remove heater outlet. "Removal and Installation". Remove camshafts. Refer to EM-54. "Removal and Installation" H Removal and Installation INFOID:0000000010709675 I NOTE: When removing components such as hoses. Remove intake manifold. 9. CAUTION: • Perform this step when the engine is cold. Cylinder head assembly 2. Refer to CO-28. Remove exhaust manifold and three way catalyst assembly. J REMOVAL 1. Refer to CO-28. 7. Drain engine coolant. cap or plug openings to prevent fluid from spill- ing. Drain engine oil. Refer to EM-27.. tubes/lines. • Do not spill engine coolant on drive belt. Refer to EM-46. Refer to EM-31. "Changing Engine Oil". M • Do not spill engine oil on drive belt. O NOTE: Can be removed and installed even when assembled with cylinder head. 2.

Follow the "Cylinder Head Bolts Outer Diameter" procedure. gasket. 13. Install new cylinder head gasket. 12. replace them with a new one. "Inspection After Disassembly".004 in) • If it exceeds the limit. KBIA0058E INSPECTION AFTER REMOVAL Cylinder Head Bolts Outer Diameter • Cylinder head bolts are tightened by plastic zone tightening method. KBIA0058E Revision: August 2014 EM-68 2015 Frontier NAM . Whenever the size difference between (d1) and (d2) exceeds the limit. NOTE: Apply new engine oil to threads and seating surfaces of bolts. Limit : 0. check their outer diameters before installation. 2. Loosen cylinder head bolts in reverse order as shown using power tool.1 mm (0. PBIC0075E INSTALLATION 1. Using suitable tool. Limit [(d1) (d2)]: 0. wipe off oil.0091 in) • If reduction of outer diameter appears in a position other than (d2). sealant and carbon deposits from surface of cylinder head. use it as (d2) point. replace cylinder head. scale. measure the distortion in six directions. At each of several locations on bottom surface of cylinder head. 1.23 mm (0. CYLINDER HEAD < REMOVAL AND INSTALLATION > [QR25DE] 11. Install cylinder head following the steps below to tighten cylinder head bolts in numerical order as shown. WBIA0836E Cylinder Head Distortion NOTE: When performing this inspection. 2. Refer to EM-91. CAUTION: If cylinder head bolts re-used. Remove cylinder head. CAUTION: Do not allow gasket fragments to enter engine oil or engine coolant passages. cylinder block distortion should also be checked. Remove cylinder head gasket.

exhaust gas. if necessary. fill to the specified level. If less than required F quantity. J • After cooling down engine. Noise will stop after hydraulic pressure rises.0 kg-m. this is normal. • Start engine. check for fuel leak. • Use procedure below to check for fuel leakage. "FOR USA AND CANADA : Fluids and Lubricants" (United States and Canada). Refill to spec- ified level. check oil/fluid levels including engine coolant and engine oil. • Summary of the inspection items: K Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level L Engine oil Level Leakage Level Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage M Other oils and fluids* Level Leakage Level Fuel Leakage Leakage Leakage N Exhaust gas — Leakage — *Power steering fluid. CYLINDER HEAD < REMOVAL AND INSTALLATION > [QR25DE] • Measure the tightening angle using Tool.1 kg-m. again check oil/fluid levels including engine oil and engine coolant. I • Warm up engine thoroughly to make sure there is no leakage of fuel. 29 ft-lb) Step d : 75° clockwise WBIA0617E D Step e : 75° clockwise 3. etc. Refer to MA-16. Installation of the remaining parts is in reverse order of removal. C Step c : 39. E INSPECTION AFTER INSTALLATION • Before starting engine. • Bleed air from passages in lines and hoses. With engine speed increased. or any oils/fluids including engine oil and engine coolant. such as in cooling system. slack in the guide may generate a pounding noise during and just after engine start. • Run engine to check for unusual noise and vibration. 37 ft-lb) Step b : Loosen to 0 N·m in the reverse order of tightening.0 N·m (5.2 N·m (4. With fuel pressure applied to fuel piping. O P Revision: August 2014 EM-69 2015 Frontier NAM . brake fluid. However. H NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation. A Tool number : KV10112100 (BT-8653-A) EM Step a : 50. • Turn ignition switch ON (with engine stopped). G age at connection points. check again for fuel leakage at connection points.

Remove spark plug. Valve guide 6. Spark plug tube 11. • Do not remove valve spring seat from valve spring. Remove valve collet. 2. Valve (EXH) 10. and remove valve. Remove valve lifter. • Identify installation positions. and store them without mixing them up. Push valve stem to combustion chamber side. Revision: August 2014 EM-70 2015 Frontier NAM . Cylinder head 7. Tool numbers : KV10116200 (J-26336-A) : KV10115900 (J-26336-20) : KV10109220 ( — ) CAUTION: • When working. Valve spring (with valve spring seat) 4. valve spring retainer and valve spring using Tool. WBIA0477E 4. • Identify installation positions. be careful not to damage valve lifter holes. Valve (INT) 9. Spark plug Disassembly and Assembly INFOID:0000000010709677 DISASSEMBLY 1. 3. Valve oil seal 5. Valve spring retainer 3. Valve collet 2. and store them without mixing them up. Valve seat 8. CYLINDER HEAD < REMOVAL AND INSTALLATION > [QR25DE] Exploded View INFOID:0000000010709676 PBIC3024E 1.

NOTE: • Install smaller pitch (valve spring seat side) to cylinder head M side. • Confirm identification color of valve spring. N Intake : Blue Exhaust : Yellow O PBIC0525E 6. Height (H) : 11. Do not remove it F unless absolutely necessary. L 5. Install valve spring retainer. "Inspection After Disassembly". 8. spark plug tube will be deformed and cannot be reused. "Inspection After Disassembly". Install valve oil seal using Tool. Refer to EM-72.488 in) J WBIA0653E K 4. Remove spark plug tube. Refer to EM-72. "Inspection After Disassembly". ASSEMBLY G 1. Refer to EM-72. Refer to EM-72. P 7.0. Install valve spring (with valve spring seat). CYLINDER HEAD < REMOVAL AND INSTALLATION > [QR25DE] 5. Install valve seat if removed.465 . if necessary. H Tool numbers : KV10115600 (J-38958) NOTE: I Install with the valve oil seal to match dimension as shown.12. Install valve. 3. When valve seat must be replaced. • Once removed. CAUTION: • Be careful not to damage cylinder head. E • Remove it from cylinder head using suitable tool.4 mm (0. Remove valve oil seal using Tool. "Inspection After Disassembly". NOTE: Install larger diameter to intake side. Install valve guide if removed.8 . Tool numbers : KV10116200 (J-26336-A) : KV10115900 (J-26336-20) : KV10109220 ( — ) Revision: August 2014 EM-71 2015 Frontier NAM . Install valve collet using Tool. A Tool numbers : KV10115600 (J-38958) EM C WBIA0478E D 6. 7. When valve guide must be replaced. 2.

"Recommended Chemical Products and Sealants". Install valve lifter. wipe off any protruding sealant on top surface of cylinder head. Apply sealant within approximately 12 mm (0. CAUTION: When working.42. b.622 . • Tap valve stem edge lightly with a plastic hammer after instal- lation to check its installed condition. Press-fit spark plug tube so that its height (H) is as specified using suitable tool. 9. • Press-fit it into cylinder head as follows: a.47 in) from edge of spark plug tube press-fit side. • Install it in the original position. SEM188A VALVE GUIDE CLEARANCE Valve Stem Diameter Revision: August 2014 EM-72 2015 Frontier NAM . Inspection After Disassembly INFOID:0000000010709678 VALVE DIMENSIONS • Check dimensions of each valve. WBIA0578E 8. "Standard and Limit". replace valve and check the valve seat contact. • After press-fitting. c.2 . 10. CYLINDER HEAD < REMOVAL AND INSTALLATION > [QR25DE] • Install valve collet with a magnet hand. Use Genuine High Strength Locking Sealant or equivalent. be careful not to damage valve lifter holes. PBIC2713E Standard press-fit : 41.1. Install spark plug. Refer to EM-108.661 in) height (H) CAUTION: • When press-fitting. Remove old sealant from cylinder head side installation hole. Refer to GI-21. • If dimensions are out of the standard. Install spark plug tube if removed. be careful not to deform spark plug tube.2 mm (1.

heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil.004 in) • If it exceeds the limit.030 .09 mm (0. K 1.053 mm (0.2 US ton.955 . replace with oversized [0.063 mm (0.5.020 .0025 in) Limit I Intake : 0.2362 .003 in) Exhaust : 0. G Valve guide clearance: Standard Intake : 0.970 mm (0.2354 in) Exhaust : 5.0021 in) H Exhaust : 0. 2. P SEM931C Revision: August 2014 EM-73 2015 Frontier NAM .0.0008 . L M N SEM008A 2.965 .6.008 in)] valve guide.0.0012 . Standard E Intake and Exhaust : 6. Drive out valve guide with a press [under a 20 kN (2 ton.0. To remove valve guide.2350 in) EM C SEM938C D Valve Guide Inner Diameter Measure the inner diameter of valve guide with inside micrometer.2344 .2 mm (0.0.2369 in) F Valve Guide Clearance (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).08 mm (0. A Standard Intake : 5. CYLINDER HEAD < REMOVAL AND INSTALLATION > [QR25DE] Measure the diameter of valve stem with micrometer.980 mm (0. when working.018 mm (0.0.000 .0. wear protective equipment to avoid getting burned.2348 . 2. replace valve guide and/or valve.5.0.0 lmp ton) force] or suitable tool. O WARNING: Cylinder head contains heat. J VALVE GUIDE REPLACEMENT When valve guide is removed.

196 mm (0.2362 . Projection (H) Intake : 10. PBIC2187E 6. wear protective equipment to avoid getting burned. CYLINDER HEAD < REMOVAL AND INSTALLATION > [QR25DE] 3.398 .3 mm (0.018 mm (0.2369 in) SEM932C VALVE SEAT CONTACT Revision: August 2014 EM-74 2015 Frontier NAM .0 .10. when working.1 .0. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil.000 .4 mm (0.0.0. Ream cylinder head valve guide hole using suitable tool.409 in) WARNING: Cylinder head contains heat. SEM008A 5.406 in) Exhaust : 10.6. Valve guide hole diameter (for service parts): Intake and exhaust : 10.4014 in) SEM932C 4.175 .10.0.4006 .10. Standard Intake and exhaust: 6. Press valve guide from camshaft side to the dimensions as shown using suitable tool.394 . Apply reamer finish to valve guide using suitable tool.

000 . Ream cylinder head recess diameter for service valve seat.1. CAUTION: When using valve seat cutter. WARNING: • Cylinder head contains heat. wear protective equipment to avoid getting burned. Set the machine depth stop to ensure this.016 mm (1. CAUTION: Prevent scratching cylinder head by excessive boring. SEM795A I 3. Force fit valve seats into cylinder head. • If not.32. H This will enable valve seat to fit correctly. 1. • Check if the contact area band is continuous all around the circum- EM ference. If the contacting surface still has NG conditions even after the re-check.1. Boring should not continue beyond the bottom face of the seat recess E in cylinder head. Then. grind to adjust valve fitting and check again. CYLINDER HEAD < REMOVAL AND INSTALLATION > [QR25DE] • After confirming that the dimensions of valve guides and valves are within specifications.5 mm (0. Refer to EM-108.37. J K L SEM008A M 4.5 mm (0. "Standard and Limit". 5. Provide valve seats cooled well with dry ice. F Oversize [0. firmly grip cutter handle with P both hands. "Standard and Limit".016 mm (1. A • Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface.000 . Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil. C SBIA0322E D VALVE SEAT REPLACEMENT When valve seat is removed. Improper pressure on the cutter or cutting many different times may result in staged valve seat.4567 .020 in)] valve seat.4573 in) G Exhaust : 32. SEM934C Revision: August 2014 EM-75 2015 Frontier NAM . Finish seat to the specified dimensions using suitable tool. replace with oversized [0.2605 in) • Be sure to ream in circles concentric to the valve guide center. 2. Refer O to EM-108.2598 . Bore out old seat until it collapses. N CAUTION: • Avoid directly touching cold valve seats. press on the contacting surface all around the circumference to cut in a single drive.020 in)] Intake : 37. perform this procedure. replace valve seat. When working.

Refer to EM-108.8 mm (0. "Standard and Limit". • If the installation load or load with valve open is out of the stan- dard.075 in) • If it exceeds the limit. PBIC0080E VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD • Check valve spring pressure with valve spring seat installed at the specified spring height. 7. VALVE SPRING SQUARENESS • Set a try square along the side of valve spring and rotate spring. CAUTION: Do not remove valve spring seat from valve spring. SEM113 Revision: August 2014 EM-76 2015 Frontier NAM . CYLINDER HEAD < REMOVAL AND INSTALLATION > [QR25DE] 6. replace valve spring. grind to adjust valve fitting. Check again for normal contact. replace valve spring.071 in) Exhaust : 1. CAUTION: Do not remove valve spring seat from valve spring.9 mm (0. Measure the maximum clearance between the top face of spring and try square. Using compound. Limit Intake : 1.

NOTE: Revision: August 2014 EM-77 2015 Frontier NAM . LH engine mounting insulator 6. follow the procedures in the applica- ble procedures. RH engine mounting bracket (upper) 2. in prep- aration for the backward shift of center of gravity. • Use either 2-pole lift type or separate type lift. attach proper slingers and bolts described in PARTS CATALOG. Rear engine mounting insulator Removal and Installation INFOID:0000000010709680 M WARNING: • Situate vehicle on a flat and solid surface. If board-on type is used for unavoidable reasons. RH engine mounting bracket (lower) 4. sup- port at the rear axle jacking point with transmission jack or similar tool before starting work. • Place chocks at front and back of rear wheels. • If items or work required are not covered by the engine section. ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > [QR25DE] UNIT REMOVAL AND INSTALLATION A ENGINE ASSEMBLY Exploded View INFOID:0000000010709679 EM C D E F G H I J AWBIA0869GB K 1. Refer to GI-33. "Garage Jack and Safety Stand". • Do not start working until exhaust system and engine coolant are cooled sufficiently. avoid forceful or uninstructed operations. • For supporting points for lifting and jacking point at rear axle. P • Always use the support point specified for lifting. LH engine mounting bracket (lower) L 7. LH engine mounting bracket (upper) 5. N • For engines not equipped with engine slingers. CAUTION: O • Always be careful to work safely. RH engine mounting insulator 3.

Refer to HA-25. 12. "Removal and Installation".2 kg-m. "Removal and Installation (Crankshaft driven type)". 20. tubes/lines. 23. Refer to EM-25.1 N·m (4. Disconnect power steering oil pump from engine and position out of the way for easier work. INSTALLATION Installation is in the reverse order of removal. "Removal and Installation". CAUTION: • When replacing an engine or transmission you must make sure the dowels are installed correctly during reassembly. always check if any harnesses are left connected. Be careful not to damage engine mounting insu- lator. Refer to CO-19. Revision: August 2014 EM-78 2015 Frontier NAM . Disconnect the heater hoses at cowl. Disconnect EVAP line. etc. "Removal and Installation". "Removal and Installation". "Removal and Instal- lation". Disconnect the engine harness grounds. 6. REMOVAL 1.. Install front and rear engine slingers. Engine slinger torque Front engine slinger : 48. 10. Refer to PG-89. "Changing Engine Coolant". Remove transmission. 13. Remove front exhaust pipe. Remove engine assembly from vehicle. Disconnect the reservoir tank for power steering from engine compartment without disconnecting the hoses and move it aside for easier work. Refer to DLK-129. • When installation directions are specified. Remove the engine cooling fan. Disconnect the engine room harness from the engine side and set it aside for easier work. 21. Remove the A/T oil level indicator and indicator tube (A/T models). ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > [QR25DE] When removing components such as hoses. cap or plug openings to prevent fluid from spill- ing. "Removal and Installation for Compres- sor". Refer to EC-466. 14. 17. 7. 19. Remove the A/C compressor bolts and set aside.9 kg-m.0 N·m (2. Refer to EM-39. avoiding interference with vehicle body. and tighten nuts and bolts. "Fuel Pressure Check". oil leaks or breakage of driv- etrain components. 8. Refer to ST- 19. 3. Disconnect brake booster vacuum line. 5. Remove the radiator assembly and hoses. • Do not allow engine oil to get on engine mounting insulator. 16 ft-lb) 22. 2. Remove the engine hood. TM-306. Disconnect the fuel hose at the engine side connection. 15. 18. "Removal and Installation". Refer to EM-31. • Make sure that each mounting insulator is seated properly. "Removal and Installation". 9. Lift with hoist and secure the engine in position. Refer to CO-16. Refer to EM-14. 16. Release fuel pressure. install parts according to the direction marks on them referring to the figure of components. Remove the air duct and resonator assembly and air cleaner case. CAUTION: • Before and during this lifting. Refer to TM-21. Refer to CO-12. Drain engine coolant. Disconnect vacuum hose between vehicle and engine and set it aside. • Improper alignment caused by missing dowels may cause vibration. 11. 4. LBIA0449E 24. "Removal and Installation of Hood Assembly". "Removal and Installa- tion for QR25DE" (A/T models). 35 ft-lb) Rear engine slinger : 22. "Removal and Installa- tion from Vehicle" (M/T models). Disconnect battery negative terminal. Remove the drive belt.

Refill to spec- ified level. If less than required A quantity. check oil/fluid levels including engine coolant and engine oil. this is normal. However. Noise will stop D after hydraulic pressure rises. slack in the guide may generate a pounding noise during and just after engine start. • Run engine to check for unusual noise and vibration. ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > [QR25DE] INSPECTION AFTER INSTALLATION • Before starting engine. check again for fuel leakage at connection points. With engine speed increased. if necessary. • Summary of the inspection items: F Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level G Engine oil Level Leakage Level Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage transaxle fluid H M/T Models Level/Leakage Leakage Level/Leakage Other oils and fluids* Level Leakage Level Fuel Leakage Leakage Leakage I Exhaust gas — Leakage — *Power steering fluid. etc. check for fuel leak- age at connection points. J K L M N O P Revision: August 2014 EM-79 2015 Frontier NAM . C NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation. • Warm up engine thoroughly to make sure there is no leakage of fuel. exhaust gas. or any oils/fluids including engine oil and engine coolant. brake fluid. "FOR USA AND CANADA : Fluids and Lubricants" (United States and Canada). EM • Turn ignition switch ON (with engine stopped). Refer to MA-16. E • After cooling down engine. such as in cooling system. • Bleed air from passages in lines and hoses. • Start engine. • Use procedure below to check for fuel leakage. fill to the specified level. With fuel pressure applied to fuel piping. again check oil/fluid levels including engine oil and engine coolant.

ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] UNIT DISASSEMBLY AND ASSEMBLY ENGINE UNIT Exploded View INFOID:0000000010709681 WBIA0837E Revision: August 2014 EM-80 2015 Frontier NAM .

Refer to EM-81. Pilot bushing (M/T models) 30. Connector protector cap Disassembly and Assembly INFOID:0000000010709682 O DISASSEMBLY NOTE: P The following procedures explain how to disassemble the engine with the engine stand fastened to the bell housing. Second ring 20. Cylinder block 2. Oil level gauge guide 9. 1. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] 1. Lower cylinder block mounting bolt 12. Knock sensor 5. Oil pressure switch 6. "Disassembly and Assembly" Assembly" E C. Water drain plug 7. Connecting rod bearing cap 16. "5M/T : Removal and Installation". O-ring 3. and separate the transmission assembly from the engine. Pilot convertor (A/T models) 29. Lower cylinder block 11. Top ring 21. "Disassembly and B. Main bearing lower 27. "Disassembly and Assembly" Assembly" Block Heater — Canada Only F G H I J K L M PBIC3021E 1. Crankshaft key 26. Rear oil seal 28. and remove bolts using a suitable tool. Reinforcement plate (A/T models) 33. Connecting rod bolt 17. Remove the engine and the transmission assembly from the vehicle. Some steps may be different if using a different type of engine stand. Thrust bearing 23. Piston pin C 22. Revision: August 2014 EM-81 2015 Frontier NAM . Remove clutch cover and clutch disc (M/T models). Cylinder block heater N 4. Gasket 3. "Disassembly and D. Refer to EM-81. Cylinder block 2. Oil ring 19. Connecting rod 14. • Secure crankshaft Tool. 2. Drive plate (A/T models) 34. Refer to CL-19. Signal plate (type 1) D 31. Refer to EM-81. O–ring 10. Signal plate (type 2) 32. Refer to EM-77. Main bearing upper 24. Refer to EM-81. Connecting rod bearing 15. 3. Remove flywheel (M/T models) using suitable tool or drive plate (A/T models) using Tool. Oil level gauge 8. Snap ring EM 13. Crankshaft position sensor (POS) A 4. Crankshaft 25. Flywheel (M/T models) A. Piston 18.

Remove the parts that may restrict installation of engine to KBIA2491E engine stand. Remove drive plate (A/T models) or flywheel (M/T models). Refer to EM-37. "Removal and Installation". "Removal and Installation" 6. c. Remove generator. some amount of noise is normal. • Loosen bolts diagonally. CAUTION: • Use an engine stand that has a load capacity [approxi- mately 240kg (529 lb) or more] large enough for support- ing the engine weight. NOTE: The flywheel. Refer to CHG-28. 5. allows movement in response to transmission side pressure. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] Tool number : KV11105210 (J-44716) CAUTION: • Be careful not to damage or scratch drive plate (A/T models) and contact surface for clutch disc of flywheel (M/T models). Therefore. lock crankshaft to remove flywheel or drive plate bolts. "Changing Engine Oil". • Remove the following parts if the engine stand load capacity is not adequate. Refer to LU-10. • Place the drive plate or flywheel with signal plate sur- face facing other than downward. • Holding crankshaft pulley bolts. • Before removing the hanging chains. . NOTE: The figure shows an example of widely used engine stand (A) that can support mating surface of transaxle with drive plate AWBIA1520ZZ removed. "Removal and Installation" .Intake manifold. Drain engine oil. or when rotated. 4. • Keep magnetic materials away from signal plate. two block construction. and mount to engine stand. Revision: August 2014 EM-82 2015 Frontier NAM . to reduce the potential risk of overturning stand: . make sure the engine stand is stable and there is no risk of overturning.Exhaust manifold. Refer to EM-27. a. Lift engine. "Removal and Installation .QR25DE Models".Rocker cover. b. Any commercially avail- able engine stand can be used. Remove engine mounting insulator bracket (upper) with power tool. Refer to EM-31.

check the connecting rod side clearance. N Tool number : ST16610001 (J-23907) O P WBIA0618E 13. "Removal and Installation". the cylinder block drain plug (3) as shown. CAUTION: Revision: August 2014 EM-83 2015 Frontier NAM . • Do not disassemble. C D E F G AWBIA1524ZZ 8. I CAUTION: • Avoid impacts such as a dropping. 12. Remove oil pressure switch using a suitable tool. H 9. Remove pilot converter (A/T models) or pilot bushing (M/T mod- els) using Tool. • Do not place the sensor in a location where it is exposed to magnetism. Remove piston and connecting rod assembly as follows: • Before removing piston and connecting rod assembly. "Inspection After Disassembly". CAUTION: Carefully handle knock sensor avoiding shocks. K L PBIC2191E 11. is not a cylinder block drain plug but a block heater. A CAUTION: Do not reuse copper sealing washer. CAUTION: M Do not drop or shock oil pressure switch. Refer to EM-91. Drain engine coolant by removing water drain plugs (1). 10. Remove cylinder head. NOTE: EM For Canada. J • Keep it away from metal particles. Remove crankshaft position sensor (POS). ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] 7. (2) and (3) from side of the engine. Refer to EM-67. Remove knock sensor.

18. PBIC1638E Revision: August 2014 EM-84 2015 Frontier NAM . Push piston and connecting rod assembly out to the cylinder head side using suitable tool. check the piston ring side clearance. be careful not to damage piston. resulting from an interference of the connecting rod big end. CAUTION: • When removing piston rings. PBIC0087E 19. • Be careful not to damage piston rings by expanding them excessively. and store them without mixing them up. 15. 16. • Remove piston rings using piston ring expander or suitable tool. • Before removing piston rings. and to scratch the surface. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. PBIC0259E 17. Remove connecting rod bearings from connecting rod and connecting rod bearing cap. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] Be careful no to drop connecting rod bearing. Remove connecting rod bearing cap. Remove piston rings from piston. 14. "Inspection After Disassembly". CAUTION: Identify installation position. Refer to EM-91. Remove snap rings using snap ring pliers. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin. Remove piston from connecting rod as follows: a.

ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] b. use a block of wood to avoid interference between signal plate and the floor surface. • Use Tool to cut liquid gasket for removal. Remove lower cylinder block bolts. NOTE: SBIA0275E Revision: August 2014 EM-85 2015 Frontier NAM . use socket (size T30). Remove lower cylinder block. CAUTION: • Be careful not damage or deform signal plate mounted on O crankshaft. I NOTE: Use socket (size E14) for bolts No. Heat piston to 60° to 70°C (140° to 158°F) with an industrial use drier or equivalent. N 22. NOTE: When removing or installing signal plate. "Inspection After Disassembly". Push out piston pin with stick of outer diameter approximately 19 mm (0. J K PBIC2718E L 21. H • Before loosening lower cylinder block bolts. Pull rear oil seal out from rear end of crankshaft.75 in). Remove crankshaft. Refer to EM-91. E F G PBIC0262E 20. 23. P • Do not remove signal plate unless it is necessary to do so. A EM C PBIC1639E D c. M Tool number : KV10111100 (J-37228) CAUTION: Be careful not to damage the mounting surfaces. measure crankshaft end play. • When setting crankshaft on a flat floor surface. 1 to 10. • Loosen lower cylinder block bolts in reverse order as shown in several different steps.

ASSEMBLY 1. dirt. AWBIA1524ZZ 3. b. Install main bearings and thrust bearings as follows: a. PBIC0264E Revision: August 2014 EM-86 2015 Frontier NAM . • Identify installation positions. • Use Genuine Silicone RTV Sealant. the cylinder block drain plug (3) as shown. WARNING: Use approved safety glasses to protect your eyes. is not a cylinder block drain plug but a block heater. NOTE: For Canada. Fully air-blow engine coolant and engine oil passages in cylinder block. use a suitable tool to remove the oil seal installed between crankshaft and cylinder block out. or scratch the surface. and store them without mixing them up. Install the thrust bearings to both sides of the No. • Install the thrust bearings with the oil groove facing the crank- shaft arm (outside). and engine oil from the bearing mating sur- faces of the cylinder block and lower cylinder block. 24. Refer to GI- 21. 2. Remove main bearings and thrust bearings from cylinder block and lower cylinder block. or equivalent. CAUTION: Be careful not to damage crankshaft and cylinder block. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] When replacing rear oil seal without removing lower cylinder block. Install the drain plugs on the cylinder block. CAUTION: Do not reuse copper sealing washer. Remove dust. "Recommended Chemical Products and Sealants". CAUTION: • Do not drop main bearing. cylinder bore and crankcase to remove any foreign material. Apply Silicone RTV Sealant to the drain plugs. 3 main bearing journal on the cylinder block.

Install crankshaft to the cylinder block. Tighten lower cylinder block bolts in three steps in the order as shown using Tool.0 N·m (2.1 N·m (2.22) : 25. 19 ft-lb) Revision: August 2014 EM-87 2015 Frontier NAM . E a. A • The main bearing with an oil hole and groove goes on the cyl- inder block. NOTE: Cylinder block and lower cylinder block are machined together. O Tool number : KV10112100 (BT-8653-A) CAUTION: P There are more processes to complete the tightening of lower cylinder bolts. "Recommended Chemical Products and Sealants". ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] c. M WBIA0160E N 7. 4. CAUTION: Do not install rear oil seal at this time. Refer to K GI-21. Position the crankshaft and signal plate using a positioning dowel pin. SBIA0278E H shaft. 3 journal has different specifications. Install the main bearings paying attention to their position and direction. However stop procedure after step 1 and install rear oil seal. Remove the dowel pin.9 kg-m. 16 ft-lb) G b. CAUTION: After liquid gasket is applied. Neither of them can be replaced separately. • Before installing the bearings. C but thoroughly clean it. and tighten the signal plate bolts to specification.2 kg-m.5 N·m (1. Do not apply oil to the back surface. align the bearing stopper to the notch.6 kg-m. apply engine oil to the bearing friction surface (inside). J 6. KBIA0063E Lower cylinder block bolts Step 1 (bolts 11 . NOTE: Dowel pins for the crankshaft and signal plate are supplied as a set for each. the lower cylinder block L installation must be finished within 5 minutes. 14 ft-lb) Type 2 : 22. EM • Only the main bearing (on the cylinder block) for No. The one without them goes on the lower cylinder block. or equivalent. NOTE: • Apply new engine oil to threads and seat surfaces of the bolts. Install the signal plate to the crankshaft. check that it turns smoothly. F Signal plate bolts Type 1 : 18. CAUTION: Be sure to remove dowel pin before installing the crank. Apply a continuous bead of liquid gasket using a suitable tool to positions shown and install the lower cylinder block. SBIA0277E • Make sure that the oil holes on the cylinder block and those on D the corresponding bearing are aligned. • When installing. I 5. • While turning the crankshaft by hand. • Use Genuine RTV Silicone Sealant.

10) : 39. SEM715A SBIA0281E CAUTION: Check tightening angle using Tool. • Insert the piston pin snap ring fully into groove. Install the piston to the connecting rod. make sure that the crankshaft can be rotated smoothly by hand.65° (target: 60°) Apply new engine oil to new rear oil seal and install it using a suitable tool. b. CAUTION: • Do not touch grease applied onto oil seal lip. WBIA0619E 8. SBIA0280E • Install new oil seal in the direction shown. Refer to EM-108. Do not tighten by visual inspection.2 N·m (4. Using a snap ring pliers. Tool number : KV10112100 (BT-8653-A) • Wipe off completely any protruding Silicone RTV Sealant on the exterior of engine. a. • Press fit oil seal straight to avoid causing burrs or tilting. Install the piston to the connecting rod. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] Step 2 (bolts 1 .0 kg-m. • After installing the bolts.10) : 60° . • Be careful not to damage crankshaft and/or cylinder block. "Standard and Limit". install the snap ring into the grooves of the piston's rear side. 29 ft-lb) Step 3 (bolts 1 . Revision: August 2014 EM-88 2015 Frontier NAM . • Check crankshaft side clearance. Assemble the components in their original positions.

Assemble the components in their original positions. Install the piston and connecting rod assembly to the crankshaft. PBIC0266E M 11. but thoroughly clean the back. • Rotate the crankshaft so the pin corresponding to the connect- ing rod to be installed is at the bottom dead center position. c. P WBIA0620E Tool number : EM03470000 (J-8037) CAUTION: Be careful not to damage the cylinder wall and crankshaft pin.158° F)] until the piston pin can be pushed in by hand without excessive force. J • When installing the connecting rod bearings. and crankshaft pin. • Check that the connecting rod moves smoothly. Assemble the components in their original positions. insert the piston pin into the piston A and the connecting rod. be careful not to damage F piston.70° C (140° . Revision: August 2014 EM-89 2015 Frontier NAM . N • Apply engine oil sufficiently to the cylinder bore. heat the piston [approximately 60° . • Assemble so that the front mark on the piston crown and the oil holes and the cylinder No. • Install the piston with the front mark on the piston crown facing the front of the engine using Tool. • Install the top ring and the second ring with the stamped sur. align the connecting rod bearing stopper pro- trusion with the notch of the connecting rod to install. PBIC0100E Stamped mark : 2ND (second ring) I 10. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] • Using a heat gun. on O the connecting rod for installation. Install the connecting rod bearings to the connecting rod and the connecting rod cap. on the connecting rod are posi- EM tioned as shown. H face facing upward. Assemble the components in their original positions. • Be careful not to damage piston rings by expanding them excessively. C D PBIC0099E E 9. Do not apply oil to the back surface. resulting from an interference of the connecting rod big end. • Check the oil holes on the connecting rod and those on the L corresponding bearing are aligned. K • When installing. CAUTION: • When installing piston rings. piston. referencing the pis- ton front mark as the starting point. apply engine oil to the bearing friction surface (inside). Using a piston ring expander. Install the piston pin snap ring into the front of the piston. install the piston rings. • Match the cylinder position number with the cylinder No. From the front to the rear. G • Position each ring with the gap as shown.

Do not ighten by visual inspection.75 in) KBIA0075E 15. make sure that the crankshaft rotates smoothly. • Install drive plate. push pilot con- verter into the end of the crankshaft. • Press fit pilot bushing into the crankshaft as shown.1 N·m (2. 16 ft-lb) Revision: August 2014 EM-90 2015 Frontier NAM . CAUTION: Check tightening angle using Tool. Install the knock sensor.2 kg-m. Install the cylinder block heater (if equipped). "Inspection After Disassembly". PBIC3020E Knock sensor bolt : 21.30 in) diameter.5 N·m (7. Step 1 : 27. 14. • Match the stamped cylinder number marks on the connecting rod with those on the cap to install. Cylinder block heater : 73.0 kg-m.95° (target 90° degrees) • Check the connecting rod side clearance. • Using a drift with 33 mm (1. Refer to EM-91. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] 12.4 N·m (2.6 N·m (2. reinforcement plate and pilot converter as shown. • Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sen- sor. • Install the knock sensor with the connector facing lower left by 45° as shown. • After tightening the bolts. 0 ft-lb) Step 3 : 19.5 kg-m. 54 ft-lb) 16.8 kg-m. SBIA0282E 13. Install flywheel (M/T Models). using a suitable drift of 19 mm (0. 20 ft-lb) WBIA0621E Step 2 : 0 N·m (0 kg-m. Assemble the compo- nents in their original positions. Install the connecting rod bearing caps. or drive plate (A/T Models). Tighten the connecting rod bolts using Tool in four steps as fol- lows: Tool number : KV10112100 (BT-8653-A) • Apply engine oil to the threads and seats of the connecting rod bolts. • Make sure that the knock sensor does not interfere with other components. • Do not tighten the knock sensor bolt while holding the connec- tor. 14 ft-lb) Step 4 : 90° .

M Standard: 19. H shaft arm with a feeler gauge. If it still exceeds the limit.0.7876 in) N O PBIC0116E Piston Pin Outer Diameter P Revision: August 2014 EM-91 2015 Frontier NAM .0. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] CAUTION: If the knock sensor is dropped.138 in) I Limit : 0. and measure again. replace connecting rod.993 .20. Installation of remaining components is in reverse order of removal. G PBIC2377E CONNECTING ROD SIDE CLEARANCE • Measure the side clearance between connecting rod and crank.20 .0039 .0.0. KBIA0071E K PISTON TO PISTON PIN OIL CLEARANCE Piston Pin Hole Diameter L Measure the inner diameter of piston pin hole with an inside micrometer. and measure again. If it still exceeds the limit. Crankshaft position : 7.0197 in) • If the measured value exceeds the limit. replace thrust bearings.71 kg-m. 62 in-lb) EM sensor bolt 18. Install the crankshaft position sensor (POS). E Standard : 0.50 mm (0. Standard : 0.30 mm (0. replace crankshaft J also.0. C Inspection After Disassembly INFOID:0000000010709683 CRANKSHAFT END PLAY D • Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator.0 N·m (0.0079 .35 mm (0.26 mm (0.10 . A 17.0118 in) F • If the measured value exceeds the limit.7871 .0102 in) Limit : 0. replace crankshaft also. replace it with new one.005 mm (0.

95 mm (0.0031 in) 2nd ring : 0.0012 . • When replacing piston and piston pin assembly.31 mm (0.0.47 mm (0.0. • Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] Measure the outer diameter of piston pin with a micrometer.0.) PISTON RING SIDE CLEARANCE • Measure the side clearance of piston ring and piston ring groove with a feeler gauge.0.0.32 .11 mm (0. Standard: Top ring : 0. and measure again. Revision: August 2014 EM-92 2015 Frontier NAM .7870 .002 .0122 in) 2nd ring : 0. "Standard and Limit".0374 in) • If the measured value exceeds the limit. If it still exceeds the limit. and measure again.030 .21 . Refer to EM-108.001 mm (0.0039 in) • If the measured value exceeds the limit.045 .989 .54 mm (0.0053 in) Limit: SEM024AA Top ring : 0.0.070 mm (0.10 mm (0. no grades can be selected. replace piston also. replace piston ring.0083 .0126 .0001 . Standard: Top ring : 0. Standard: 19.20. (Only grade “0” is available.0.0185 in) Oil ring (rail ring) : 0. • Lubricate with new engine oil to piston and piston ring.0002 in) • If oil clearance is out of the standard.135 mm (0.60 mm (0.0. replace piston and piston pin assembly. NOTE: • Piston is available together with piston pin as assembly.7874 in) PBIC0117E Piston to Piston Pin Oil Clearance (Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter) Standard: 0. and measure piston ring end gap with a feeler gauge. "Standard and Limit".0079 . replace piston ring.0213 in) 2nd ring : 0.065 .0028 in) Oil ring : 0.0. For service parts.0.0043 in) 2nd ring : 0.006 mm (0.0.0236 in) SEM822B Limit: Top ring : 0.0018 . and then insert piston ring until middle of cylinder with piston. PISTON RING END GAP • Make sure that cylinder bore inner diameter is within the specifica- tion.20 .65 mm (0.0.0. Refer to EM-108.0256 in) Oil ring (rail ring) : 0.080 mm (0.0026 .0.0.

K PBIC1641E L CONNECTING ROD BUSHING OIL CLEARANCE Connecting Rod Bushing Inner Diameter M Measure the inner diameter of connecting rod bushing with an inside micrometer. D E F G PBIC2077E CONNECTING ROD BIG END DIAMETER H • Install connecting rod bearing cap without connecting rod bearing installed. Refer to EM-81. A Bend: Limit: 0.000 .94 in) length EM Torsion: Limit: 0.8898 .8903 in) J • If out of the standard. Standard: 48.15 mm (0.0118 in) per 100 mm (3. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] CONNECTING ROD BEND AND TORSION • Check with a connecting rod aligner. replace connecting rod assembly. "Disassembly and Assembly" for the tightening procedure. Standard: 20.0059 in) per 100 mm (3.7879 in) N O P PBIC0120E Piston Pin Outer Diameter Revision: August 2014 EM-93 2015 Frontier NAM .94 in) length C • If it exceeds the limit.0. and tightening connecting rod bolts to the specified torque.48.20.013 mm (1. replace connecting rod assembly.000 .7874 . • Measure the inner diameter of connecting rod big end with an I inside micrometer.1.30 mm (0.012 mm (0.

006 20.19.20.001 Piston pin outer diameter (0. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] Measure the outer diameter of piston pin with a micrometer.989 .0.7874 in) PBIC0117E Connecting Rod Bushing Oil Clearance (Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame- ter) Standard: 0.012 inner diameter* (0.7876 . 005 Piston pin hole diameter (0.7870 .0.001 mm (0.0. Refer to EM-108. using suitable tool. PBIC3019E CYLINDER BLOCK DISTORTION • Remove gasket on the cylinder block surface.20. or other contami- nation.017 mm (0. Unit: mm (in) Grade 0 1 Connecting rod bushing 20.19.7870 . "Standard and Limit". PBIC2196E Factory installed parts grading: • Service parts apply only to grade “0”.999 19.7872 .7874 .7871 .20.995 . • If replacing connecting rod assembly.7879) 19. Standard: 19.7874 . Refer to EM-108.7874) *: After installing in connecting rod. and also remove engine oil.0.7876) (0.993 . Revision: August 2014 EM-94 2015 Frontier NAM .7872) (0. "Standard and Limit" to select connecting rod bearing.0. • If replacing piston and piston pin assembly. replace connecting rod assembly and/or piston and piston pin assembly. carbon.0.0.20.005 .7874) (0.989 . CAUTION: Do not allow any debris to enter engine oil or engine coolant passages.0. scale.995 19.20.006 .0002 .0.999 .0007 in) • If the measured value is out of the standard.000 .7876) 19.

015 mm (0. measure cylinder bore at (B) position.0004 in) • If the measured value exceeds the limit. J NOTE: When determining cylinder bore grade. because it is PBIC2012E machined together with lower cylinder block.0006 in) Taper limit [Difference between (A) and (C)]: N 0.944 . and tighten lower cylinder block bolts to the specified torque. because it is C machined together with lower cylinder block. (B) and (C)] [(Y) is in longitudinal direction of the engine]. Refer to EM-81.58.010 . H PISTON TO CYLINDER BORE CLEARANCE Cylinder Bore Inner Diameter • Using a bore gauge. replace cylinder block and lower cylinder EM block assembly. replace cylinder block and lower cylinder block assembly.5051 in) L Wear limit: SBIA0284E 0. G NOTE: Cylinder block cannot be replaced as a single part. K Standard inner diameter: 89.3216 in) • If out of the standard. O Piston Skirt Diameter P Revision: August 2014 EM-95 2015 Frontier NAM .01 mm (0. F Standard: 58.89.004 in) • If it exceeds the limit. measure the cylinder bore for wear.008 in) Out-of-round [Difference between (X) and (Y)]: M 0. E • Measure the inner diameter of main bearing housing with a bore gauge. out-of.3.2. NOTE: Cylinder block cannot be replaced as a single part.5043 . "Disassembly and Assembly" for the tightening procedure.3206 . ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] • Measure the distortion on the cylinder block upper face at some different points in six directions with straightedge and feeler gauge. hone or re-bore the cylinder inner wall.030 mm (3.2 mm (0. [(X) and (Y) directions at (A). I round and taper at six different points on each cylinder.1 mm (0.968 mm (2. or if there are scratches and/or seizure on the cylinder inner wall. A Limit: 0. PBIC0121E D MAIN BEARING HOUSING INNER DIAMETER • Install lower cylinder block without main bearings installed.

1636 . (Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter) Standard : 0.C where. D: Bored diameter A: Piston diameter as measured B: Piston .955 .to . • Do not cut too much out of cylinder bore at a time. replace piston and piston pin assembly. Re-bored size calculation: D = A + B . NOTE: • When any cylinder needs boring. Then use undersize bearing.692 in) Standard : 88.0004 .0031 in) • If it exceeds the limit. Otherwise.3.5043 in) PBIC0125E Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter [direction (X).54. Standard: 54. "How to Select Piston and Bearing". position (B)]. 3. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter. Measure point : Distance from the top 42. 4. and tighten bolts to the specified torque. Measure the finished cylinder bore for out-of-round and taper.0020 in) or so in diameter at a time. "Standard and Limit". 5.030 mm (0. Cut only 0. Re-boring Cylinder Bore 1.2. Install lower cylinder block.0. NOTE: Measurement should be done after cylinder bore cools down.98 mm (1. measure the main bearing oil clearance. "Disassembly and Assembly" for the tightening procedure. Refer to EM-108.1645 in) dia.0012 in) Limit : 0. all other cylinders must also be bored.0008 in) 2. • If out of the standard.08 mm (0.990 . Hone cylinders to obtain the specified piston to cylinder bore clearance. Refer to EM-81. Cut cylinder bores. CRANKSHAFT MAIN JOURNAL DIAMETER • Measure the outer diameter of crankshaft main journals with a micrometer.5035 . PBIC0270E CRANKSHAFT PIN JOURNAL DIAMETER Revision: August 2014 EM-96 2015 Frontier NAM .0. cylinder bores may be dis- torted in final assembly.89.979 mm (2.010 mm (3.cylinder bore clearance (standard value) C: Honing allowance 0.05 mm (0.010 . Refer to EM-101. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] Measure the outer diameter of piston skirt with a micrometer.02 mm (0.

"Standard and Limit". 3 journal. C • Out-of-round is indicated by the difference in dimensions between (X) and (Y) at (A) and (B). "Standard and Limit". replace crankshaft. measure the connecting rod bearing oil clearance. select proper connecting rod O bearing according to connecting rod big end diameter and crank- shaft pin journal diameter to obtain the specified bearing oil clear- ance. • Measure the inner diameter of connecting rod bearing with an M inside micrometer. EM OUT-OF-ROUND AND TAPER OF CRANKSHAFT • Measure the dimensions at four different points as shown on each main journal and pin journal with a micrometer.0025 mm (0. "Disassembly and Assembly" for tightening procedure.0. avoiding oil holes.035 .0014 . • Place a dial indicator straight up on the No. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] • Measure the outer diameter of crankshaft pin journal with a micrometer. K PBIC2541E CONNECTING ROD BEARING OIL CLEARANCE L Method by Calculation • Install connecting rod bearings to connecting rod and cap.974 mm (1. Refer to EM-108. • Taper is indicated by the difference in dimension between (A) and D (B) at (X) and (Y). CRANKSHAFT RUNOUT H • Place a V-block on a precise flat table to support the journals on the both end of crankshaft. Refer to EM-108. and place it in crankshaft axial direction. Limit: E Out-of-round [Difference between (X) and (Y)] : 0. Then use undersize bearing. Refer to EM-81.0001 in) • If the measured value exceeds the limit. Refer to EM-101. correct or replace crankshaft.7706 in) dia.0018 in) • If the clearance exceeds the limit.7699-1.045 mm (0. (Total indicator reading) Limit : 0. G • If corrected. Then select main bearing and/or connecting rod bearing.956 . measure the bearing oil clearance of the corrected main journal and/or pin journal. • Cut a plastigage slightly shorter than the bearing width.0001 in) PBIC2203E Taper [Difference between (A) and (B)] F : 0. Refer to EM-81. "Disassembly and Assembly" for the tightening procedure. and tighten connecting rod bolts to the specified torque. "How to Select Piston and Bearing".05 mm (0. A Standard: 44. read the movement of the pointer on the I dial indicator. Revision: August 2014 EM-97 2015 Frontier NAM . (Bearing oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter) N Standard : 0. • While rotating crankshaft.0020 in) J • If it exceeds the limit.44. • If out of the standard.0025 mm (0. • Install connecting rod bearings to connecting rod and cap.0. and tighten connecting rod bolts to the specified torque. PBIC1642E P Method of Using Plastigage • Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.

004 in) PBIC2204E • If the clearance exceeds the limit. • Remove connecting rod cap and bearing.0. 2 and 4 journals : 0.0016 . select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain the specified bearing oil clearance. and place it in crankshaft axial direction.1 mm (0. CAUTION: Do not rotate crankshaft.0. and using the scale on the plastigage bag. and tighten lower cylinder block bolts to the specified torque. • Measure the inner diameter of main bearing with a bore gauge. and using the scale on the plastigage bag.028 . measure the plastigage width. "Disassembly and Assembly" for the tightening procedure. avoiding oil holes.0022 in) Limit : 0. Method of Using Plastigage • Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely. • Install main bearings to cylinder block and lower cylinder block. Refer to EM-101. and tighten lower cylinder block bolts to the specified torque. 3 and 5 journals : 0.056 mm (0. NOTE: The procedure when the measured value exceeds the limit is same as that described in the “Method by Calculation”. "Disassembly and Assembly" for the tightening procedure.042 mm (0.0. • Cut a plastigage slightly shorter than the bearing width. "How to Select Piston and Bearing". Refer to EM-81. NOTE: The procedure when the measured value exceeds the limit is same as that described in the “Method by Calculation”. PBIC1149E MAIN BEARING OIL CLEARANCE Method by Calculation • Install main bearings to cylinder block and lower cylinder block. • Remove lower cylinder block and bearings. (Bearing oil clearance) = (Main bearing inner diameter) – (Crank- shaft main journal diameter) Standard: No. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] CAUTION: Do not rotate crankshaft. PBIC1149E MAIN BEARING CRUSH HEIGHT Revision: August 2014 EM-98 2015 Frontier NAM .0011 .041 .0017 in) No.0. 1. Refer to EM-81. measure the plastigage width.

• Measure the outer diameters [(d1).3051 in) • When (d) falls below the limit (when it becomes thinner). EM Standard: There must be crush height. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] • When lower cylinder block is removed after being tightened to the specified torque with main bearings installed. the tip end of bearing must protrude. Standard: There must be crush height.92 in) radius from the center of flywheel.13 mm (0. F • If the standard is not met.75 mm (0. regard it as (d). "Disassembly E and Assembly" for the tightening procedure. K PBIC0911E CONNECTING ROD BOLT OUTER DIAMETER L • Measure the outer diameter (d) at position as shown. replace J lower cylinder block bolt with a new one. M Limit: 7. Refer to EM-81. C SEM502G D CONNECTING ROD BEARING CRUSH HEIGHT • When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed. replace connecting rod bolt with a new one.0051 in) • If it exceeds the limit (a large difference in dimensions). Movement Amount of Thrust (Fore-and-Aft) Direction • Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10. the tip end of bearing A must protrude. • If the standard is not met. Standard : 1. (d2)] at two positions as shown. Refer to EM-81. replace connecting rod bearings. N O PBIC0912E MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS) P CAUTION: Do not disassemble double mass flywheel. • If reduction appears in a position other than (d). I Limit [(d1) – (d2)]: 0. replace main bearings. • If reduction appears in (A) range. 22 lb) force is added at the portion of 125 mm (4.051 in) or less Revision: August 2014 EM-99 2015 Frontier NAM . regard it as (d2).2 kg.3 mm (0. "Disassembly and Assembly" for the tightening procedure. G PBIC1646E LOWER CYLINDER BLOCK BOLT OUTER DIAMETER H • Perform only with M10 bolts.

Movement Amount in Radial (Rotation) Direction Check the movement amount of radial (rotation) direction with the following procedure: 1. • If anything is found. Measure the dimensions of movement amounts (A) and (B) on circumference of flywheel on the transmission side. • Tighten bolt at a force of 9. replace flywheel.0 kg-m. and mark the movement amount on the mass on the transmis- sion side.8 N·m (1. PBIC1263E • If measured value is out of the standard. 3. take care not to damage or scratch it. 87 in-lb) to keep it from loosening. 87 in-lb) in each direction. • When handling signal plate. Standard: 44.0 kg-m.744 in) or less. replace drive plate. DRIVE PLATE (A/T MODELS) • Check drive plate and signal plate for deformation or cracks. replace flywheel. and place a torque wrench on the extended line of the flywheel center line. Install a bolt to clutch cover mounting hole. PBIC2938E Revision: August 2014 EM-100 2015 Frontier NAM . Apply a force of 9.3 mm (1. Put a mating mark on circumferences of the two flywheel masses without applying any load (Measurement standard points). • Do not place drive plate with signal plate facing down. 2. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] • If measured value is out of the standard.8 N·m (1. 4. CAUTION: • Do not disassemble drive plate. • Handle signal plate in a manner that prevents it from becom- ing magnetized.

K and select piston of the same grade. C der block bearing housing Between cylinder block and Main bearing grade (bearing grade (inner diameter of hous- Main bearing crankshaft thickness) ing) and crankshaft journal grade (outer diameter of jour. J HOW TO SELECT PISTON When New Cylinder Block Is Used • Check the cylinder bore grade on rear-left side of cylinder block.) Between piston and connecting G — — — rod* *For the service parts. follow the applicable procedures. the reuse standards and the selection method of the selective fitting parts. the grade for fitting cannot be selected between piston pin and connecting rod.) The information at the shipment from the plant is described as a reference. measure the dimension accurately. • For details of the measurement method of each part. • If there is a corrected stamp mark on cylinder block. D nal) Combining service grades for connecting rod big end diame. Determine the grade by comparing the I measurement with the values of each selection table. L M N SBIA0283E O P PBIC3019E When Cylinder Block Is Reused Revision: August 2014 EM-101 2015 Frontier NAM . This grade cannot apply to reused parts. H • The identification grade stamped on each part is the grade for the dimension measured in new condition. E Between crankshaft and con. HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] HOW TO SELECT PISTON AND BEARING A How to Select Piston and Bearing INFOID:0000000010709684 DESCRIPTION EM Selection points Selection parts Selection items Selection methods Determined by match of cylin. (Only grade “0” is available. use it as a cor- rect reference. Piston grade (piston skirt diam. Connecting rod bearing grade Connecting rod bearing ter and crankshaft pin outer di- necting rod (bearing thickness) ameter determine connecting rod bearing selection. • For reused or repaired parts. F Piston and piston pin assembly Between cylinder block and pis. Piston grade = cylinder bore (piston is available together with ton eter) grade (inner diameter of bore) piston pin as an assembly.

Revision: August 2014 EM-102 2015 Frontier NAM . • The piston pin (piston pin hole) grade is provided only for the parts installed at the plant.) HOW TO SELECT CONNECTING ROD BEARING When New Connecting Rod and Crankshaft Are Used 1. "Inspection After Disassembly". For service parts. (Only grade “0” is available. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the “Piston Selection Table”.3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection Table”.5035 .020 . PBIC2198E 3.89.990 . Apply the measured dimension to the “Connecting Rod Bearing Selection Table”. 3.3.5047 .89. Measure the cylinder bore inner diameter. 4. no grades can be selected. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection Table”. 2.010 .010 (3.5047) 89.5051) Piston skirt diameter 88. HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] 1.000 . When Crankshaft and Connecting Rod Are Reused 1.89. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.89. PBIC2196E 2. Refer to EM-91. "Inspection After Disassembly" and EM-91.5043) NOTE: • There is no piston grade “1”.020 (3. • Piston is available together with piston pin as an assembly.5039) 89. Apply crankshaft pin journal diameter grade stamped on crank- shaft front side to the column in the “Connecting Rod Bearing Selection Table”.000 (3. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing. 2.3.030 (3. 4.3.5043 .5039 . 3. Apply connecting rod big end diameter grade stamped on con- necting rod side face to the row in the “Connecting Rod Bearing Selection Table”. Piston Selection Table Unit: mm (in) Grade number (Mark) 2 (or no mark) 3 Cylinder bore Inner diameter 89. "Inspection After Disassembly". Refer to EM-91. Select piston of the same grade. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi- vidually.

0593) (0. use undersize (US) bearings.0.505 .0589) (0. HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] Connecting Rod Bearing Selection Table A EM C D E F G H I J WBIA0838E K Connecting Rod Bearing Grade Table Unit: mm (in) L Grade number* 0 1 2 3 4 1.0588 . N Undersize Bearings Usage Guide • When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings.0591 . CAUTION: P Revision: August 2014 EM-103 2015 Frontier NAM .499 1.0.505 1. and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.493 .508 Thickness (0.1.0593 .1.1.496 .499 .0590) (0.0.0590 .0594) M Identification col- Black Brown Green Yellow Blue or *: Always check with the Parts Department for the latest parts information.1.502 1. O • When using undersize (US) bearing.1. measure the connecting rod bearing inner diameter with bearing installed.0591) (0.0589 .502 .0.496 1.0.

5 . 3.1.0642) HOW TO SELECT MAIN BEARING When New Cylinder Block and Crankshaft Are Used 1. Refer to EM-91. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”. 1.25 (0. 2. One is for odd-numbered journals (No. "Inspection After Disassembly". 4. PBIC2200E Bearing undersize table Unit: mm (in) Size Thickness US 0. This is due to differences in the specified clearances. • If there is a corrected stamp mark on cylinder block. When Cylinder Block and Crankshaft Are Reused 1. Apply the measured dimension to the “Main Bearing Selection Table”.624 .0639 .1. “Main Bearing Selection Table” rows correspond to main bearing housing grade on rear-left side of cylinder block. Apply main journal diameter grade stamped on crankshaft front side to column in the “Main Bearing Selection Table”. 2 and 4).632 (0.0.067 in)]. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main journal diameter individually. "Inspection After Disassembly" and EM-91. NOTE: Service part is available as a set of both upper and lower.7 mm (0.059 . Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing. Make certain to use the appropriate table. Revision: August 2014 EM-104 2015 Frontier NAM . 3 and 5) and the other is for even-numbered journals (No. CAUTION: There are two main bearing selection tables. PBIC2198E 3. HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] In grinding crankshaft pin to use undersize bearings. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”. keep the fillet R [1.0098) 1. SBIA0283E 2.0. use it as a correct reference.

1. 3 and 5 journals) C D E F G H I J K L M PBIC2201E N O P Revision: August 2014 EM-105 2015 Frontier NAM . EM NOTE: Service part is available as a set of both upper and lower. 4. Main Bearing Selection Table (No. One is for odd-numbered journals (No. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing. 2 and 4). This is due to differences in the specified clearances. 1. Make certain to use the appropriate table. 3 and 5) and A the other is for even-numbered journals (No. HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] CAUTION: There are two main bearing selection tables.

985 (0. 5 1.979 (0.0.1.0784) Pink 6 1.0781) Yellow Grade and color are the same 4 1.994 (0.1.0778 .0.1.0779.988 .0778) Black 1 1.997 (0.0785 .0783) Blue for upper and lower bearings.982 (0.1.0780 .1.988 (0.0786) White Revision: August 2014 EM-106 2015 Frontier NAM .0.0.0777 .976 (0.979 .0783 .991 .0784 . 2 and 4 journals) PBIC2202E Main Bearing Grade Table (All Journals) Unit: mm (in) Grade number* Thickness Identification color Remarks 0 1.0780) Green 3 1.1.973 . HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] Main Bearing Selection Table (No.0.985 .991 (0.1.982 .0781 .0.0779) Brown 2 1.0.994 .0785) Purple 7 1.1.0.976 .

0783 .106 .0783 .994 .25 (0.988 .973 .0780 .0098) 2. and H grind main journal so that the main bearing oil clearance satisfies the standard. I J K PBIC2200E L Bearing undersize table Unit: mm (in) Size Thickness M US 0.0.0.0781) Yellow C Grade and color are different UPR 1.985 .0778) Black 01 LWR 1.0780 .0.0.982 (0.1.982 .0778 . CAUTION: In grinding crankshaft main journal to use undersize bearings.0784 .979 . 34 LWR 1.979 . keep fillet R [1.0.0829 .059 .1.114 (0.0779 .988 .985 (0.991 (0.1.0.988 (0.0.1.0784 .0781 .0783) Blue 45 LWR 1.0784) Pink E 56 LWR 1.1.997 (0. • When using undersize (US) bearing.0.979 (0.985 .0783) Blue D UPR 1.991 .982 . Undersize Bearing Usage Guide G • When the specified main bearing oil clearance is not obtained with standard size main bearings.1.0784) Pink UPR 1.985 (0.0778 . HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE] Grade number* Thickness Identification color Remarks A UPR 1.1.1.1.994 (0.0.0785) Purple UPR 1.0.0780) Green UPR 1.982 (0.1.979 (0.0779) Brown UPR 1.0777 .0779.991 (0.1.0781) Yellow for upper and lower bearings.2.067 in)].1.994 (0.991 . measure the main bearing inner diameter with bearing installed.0.0832) N O P Revision: August 2014 EM-107 2015 Frontier NAM .1.1.1.7 mm (0.976 .0.0780) Green 23 LWR 1.0779) Brown EM 12 LWR 1.0.988 (0.976 . use under- size (US) bearing.0785) Purple 67 F LWR 1.0.0781 .0.0785 .976 (0.0.5 .0786) White *: Always check with the Parts Department for the latest parts information.

14) DRIVE BELT Tension of drive belt Auto adjustment by auto-tensioner EXHAUST MANIFOLD AND THREE WAY CATALYST ASSEMBLY Unit: mm (in) Item Limit Surface distortion 0.043 in) *: Always check with the Parts Department for the latest parts information.488 (151. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit INFOID:0000000010709685 GENERAL SPECIFICATIONS Cylinder arrangement In-line 4 Displacement 3 2.012) SPARK PLUG Make NGK Standard type* PLZKAR6A–11 Gap (nominal) 1.1 mm (0.0 x 100.0 (3.5 Standard 1.3 (0.937) Valve arrangement DOHC Firing order 1-3-4-2 Compression 2 Number of piston rings Oil 1 Compression ratio 9.108 (11.504 x 3. 161) kPa (kg/cm2. 189) Compression pressure Minimum 1.304 (13.0. CYLINDER HEAD Unit: mm (in) Items Limit Head surface distortion 0.1 (0.3.004) Items Standard Revision: August 2014 EM-108 2015 Frontier NAM .82) cm (cu in) Bore and stroke mm (in) 89. psi) / 250 rpm Differential limit between cylinders 100 (1.3.

5 .5 .5.980 (0.955 .213) Intake 97.8252) Valve length “L” Exhaust 98.25.8 (1.1.660 .970 (0.0.2344 .201 .1.409) P Exhaust 30.2350) Revision: August 2014 EM-109 2015 Frontier NAM .398 .5.0.35.2348 .30.2354) Valve stem diameter “d” Exhaust 5.8 (1.965 .1.0112) EM C D PBIC0283E E VALVE Valve Timing F G Valve timing H I PBIC0187E Unit: degree J a b c d e f 236 224 -4 60 32 37 K Valve Dimensions Unit: mm (in) L M N O SEM188A Valve head diameter “D” Intake 35.685 (1.16 (3.8905) Intake 5.0102 .82 (3. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] Items Limit A Camshaft bearing surface length 25.

04 (0.0.2772) 704 7.2740) 696 6.2850) 724 7.2882) 732 7.28 (0.0.051) Valve Clearance Unit: mm (in) Items Cold Hot* (reference data) Intake 0.2803) 712 7.043) Valve margin “T” Exhaust 1.0.013) 0.009 .3 (0.416 (0.10 (0.20 (0.00 (0.2866) 728 7.32 (0.2835) 720 7.34 (0.432 (0.38 (0.0.06 (0.24 (0.010 .2756) 700 7.2780) 706 7.34 (0.017) *: Approximately 80°C (176°F) Available Valve Lifter Thickness mm (in) Identification mark* KBIA0119E 6.96 (0.013) 0.012 .016) Exhaust 0.2811) 714 7.26 (0.308 .0.2827) 718 7.2874) 730 7.2890) 734 7.16 (0.12 (0.2898) 736 7.36 (0.2858) 726 7.2843) 722 7.02 (0.30 (0.24 .2787) 708 7.18 (0.2764) 702 7.2913) 740 Revision: August 2014 EM-110 2015 Frontier NAM .2748) 698 7.2906) 738 7.2819) 716 7.32 (0.0.304 .012 .45°45′ Exhaust Intake 1.22 (0.0.14 (0.98 (0.08 (0.2795) 710 7.0.1 (0. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] Intake Valve seat angle “α” 45°15′ .40 (0.26 .

2937) 746 EM *: Always check with the Parts Department for the latest parts information.10.196 (0.0.2369) Cylinder head valve guide hole diameter 9.0022) Valve Guide I Unit: mm (in) J K L PBIC0184E M Items Standard part Service part Valve guide Outer diameter 10.0.063 (0. 71 .018 (0.30 mm (1.36.0.10.0.29 .3378) Valve lifter hole diameter 34.0.056 (0.023 .33.7213 .3946 .30 mm (1.075 in) F Valve Lifter Unit: mm (in) G Items Standard Valve lifter outer diameter 33.3 (0.81 lb) Identification color Pink Green Squareness limit 1.0008 .7291 in) 45.42 (0.4029) N Inner diameter (Finished size) 6.8 kg.175 N (15.390 in) Installation load 151 .1.175 .1.409) Valve Seat Revision: August 2014 EM-111 2015 Frontier NAM .223 . Valve Spring C Items Intake Exhaust Free height 43.0.7909 in) D Installation height 35.4 (0.1 .398 .3935) 10.10.0.965 .76 mm (1.0008 .4 .9.0023) O Items Standard Limit Intake 0.9 kg.021 (1.0011 .39 lb) Height during valve open 25.46 (0.996 (0.0.8 kg. 34 .8 mm (0.0.027 .0.034 (0.44 (0. 34 .234 (0.0.980 (1.030 .0012 .020 .004) Intake 10.0535 in) E Load with valve open 351 .92 mm (1.10.4 .45.394 N (35.003) Valve guide clearance P Exhaust 0.7831 .40.975 .059 (0.4006 . SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] Thickness mm (in) Identification mark* A 7.3927 .4014) Interference fit of valve guide 0.0025) 0.9 mm (0.071 in) 1.2921) 742 7.996 in) 26.1.0021) 0.10.08 (0.000 .3950) 10.2362 .49 mm (1.4 .3386 .406) Projection length “L” Exhaust 10.390 in) 35.2 kg.175 N (15.0.89 lb) 318 .3 mm (0.1.72 .394 .0.43.3372 .39 lb) 151 .2929) 744 7.020 .0 . 79 .34.362 N (32.0.000 .17.8 .0.4025 .3394) H Valve lifter clearance 0.053 (0.17.6.09 (0.

2644) Intake 0.0.113 (0.0.5.1.2402 .382 .201) Height “h” Exhaust 5.390) Diameter “d2”*2 Exhaust 29.1.0.1972) Depth “H” 6.5 (1.600 .4408 .0033 .42.0 (0.0.8 .232 .0 (1.1.232 .319) Diameter “d1”*1 Exhaust 28.084 .0 (0.02)] (Service) Intake 36.37.6.0.90°15′ Intake 120° Angle “α3” Exhaust 120° Intake 1.4415) 37.2598 .116 (0.2605) Intake 36.0492 .622 .4370 .25 .35 (0.0531) Contacting width “W”*3 Exhaust 1.0.236) *1: Diameter made by intersection point of conic angles α1 and α2 *2: Diameter made by intersection point of conic angles α2 and α3 *3: Machining data Valve Seal Unit: mm (in) Items Standard Valve seal installed height 11.0610) Intake 5.36.500 .081 .1.4376) 37.1.4611) Valve seat outer diameter “d” Exhaust 31.516 (1.12.5.1.4573) Cylinder head seat recess diameter “D” Exhaust 31.9 .0 (0.37.4 (0.4567 .1.2638 .100 .113 (1. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] Unit: mm (in) PBIC2745E Items Standard Oversize [0.2 (1.1933 .0.91 .1.236) 5.488) Spark Plug Tube Unit: mm (in) Items Standard Spark plug tube installed height 41.1.31.197 .1 .236) 4.1.116 (1.3 (1.0.2447) 32.90°15′ Angle “α2” Exhaust 88°45′ .0044) Valve seat interference fit Exhaust 0.185) Intake 60° Angle “α1” Exhaust 60° Intake 88°45′ .6.36.05 .613 (1.2408) 32.465 .32.1 (1.1 (0.4605 .5 (0.597 .35.016 (1.102) Intake 35.1.097 .1.0.2441 .32.1.616 (1.661) CAMSHAFT AND CAMSHAFT BEARING Revision: August 2014 EM-112 2015 Frontier NAM .55 (0.9 .2 .30.000 .500 .01 (0.0.0046) Intake 33.177 .0 .9 .31.000 .016(1.0413 .0.516 (1.0032 .

5 23.0018 .25.7388) Camshaft runout [TIR*2] Less than 0.115 . 3. 4.45.1024 .28.0074) — D Intake 45.5047 . 1 27.205 (1.9260) — No.89.5047) Standard* Cylinder bore Inner diameter Grade No.5043 .086 (0.1032) — Camshaft bracket inner diameter EM No.01 (0.1.2 (0. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] Unit: mm (in) Items Standard Limit A Camshaft journal oil clearance 0. 5 23.0045 .800 .9234) — C Camshaft journal length No.000 .0998 .008) P Out-of-round (Difference between “X” and “Y”) 0.1. 3 89.021 (1.0.008)*1 Exhaust 43.015 .020 .020 (3. 4.0034) — No.0008) — E Camshaft sprocket runout [TIR*2] — 0. 2 89.004) O Grade No.521 (0.0059) F G H SEM671 I *1: Cam wear limit *2: Total indicator reading J CYLINDER BLOCK Unit: mm (in) K L M N PBIC0281E Surface distortion Limit 0.0.0006) Limit Taper (Difference between “A” and “C”) 0.500 .27.045 . 1 28.0176) — Camshaft end play 0.0004) Revision: August 2014 EM-113 2015 Frontier NAM .0.02 (0.188 (0. 2.935 .2 (0.1.975 . 2.0.1006) — Camshaft journal outer diameter No.955 (1.015 (0.9252 .1.23.23.1.5051) Wear limit 0.848 (1.0. 3.1 (0. 1 25.3.9226 .7313 .0157 .15 (0.0.455 (0.010 .030 (3.7797) Camshaft cam height “A” 0.435 .165 (1.44.7722 .89.3.

3213 .2. S 58. C 58.947 (2.966 . M 58.0.3210) Grade No.58.7871 .2.963 .948 .962 .964 .030 .08 (0. Y 58.952 . A 58.005 (0.3211) Grade No.2. E 58.968 (2.953 (2.0004 .947 .010 (3.2.990 .945 .3215) Grade No.58.58. 0 19.58.2.58.3213) Grade No.3207) Grade No.0012) PISTON.3207) Grade No.3215) Grade No.3208 .3213 .010 . T 58.3214) Grade No.957 .58. H 58.954 (2.958 (2.5043) Piston height “H” dimension 42. F 58. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] Grade No.2.2.20.03 (0.89.0.953 . 3 89.3209) Grade No.3208) Grade No.3214 . 2 88.961 (2.3.3215 . L 58.000 .952 (2.000 (3.951 .58.135 (0.0026 .58.7876) Standard 0.949 .0.11 (0.692) Grade No.960 .3209 .948 (2.0012 .0028) 0. V 58.3212 .0012) Piston to cylinder bore clearance Limit 0. G 58.3212) Grade No.961 . U 58.0031) 0.3211 .58.0031) *: Always check with the Parts Department for the latest parts information.2.946 (2.58.3207 .3212) Grade No.999 (0.58.58.0.0.2.19. 7 58.3211 .3207) Grade No.89.993 .030 (0.965 (2.0.3209) Grade No.3215 . Piston Ring Unit: mm (in) Items Standard Limit Top 0.58.3214 .5039) Grade No.3209 .958 .3216) Difference in inner diameter between cylinders Standard Less than 0.58.946 .98 (1.956 .3209) Grade No.58.954 .2.3210) Grade No.3208) Grade No.999 . N 58.045 .967 .951 (2.3207 .3. J 58.58.2.3214) Grade No.955 .957 (2.0018 .070 (0. B 58.080 (0.3215 .2.58.0.3213) Grade No. P 58.963 (2.3208 .2.2.065 .3211) Grade No.964 (2.58.950 .3213 .956 (2.3213) Grade No. PISTON RING AND PISTON PIN Available Piston Unit: mm (in) PBIC0188E Grade* Dimension Piston skirt diameter “A” Standard Grade No.2.58.3210 . 4 58.0039) Oil ring (rail ring) 0.967 (2.0053) — Revision: August 2014 EM-114 2015 Frontier NAM .2.0043) Side clearance 2nd 0. W 58.962 (2.3207 .945 (2.58.959 (2. X 58.58.0.2. R 58.2.5035 .58.955 (2.0. K 58.2. D 58.0.3212 .10 (0.950 (2.2.944 .7874 .2.959 .58.7874) Piston pin hole diameter Grade No. 1 19.3206 .2.58.3215) Grade No.3211) Main bearing housing inner diameter grade Grade No.5039 .965 .966 (2.3211 .2.3210 .3209 .949 (2.2.960 (2.

003 .006 .0.8900 .65 (0.48.8901) K Grade No.0.1.8899) Grade No.21.0197) Grade No.004 .20 .0079 .48. 7 48.1.7879) H Standard 0.1.48.013 (1. 8 48.0.35 (0.0.0.001 (0.8900) Grade No.8899) J Grade No.8902 .8898 .54 (0.1.010 (1.7876) Connecting rod bushing inner diameter2 Grade No.0.006 .32 .8902) L Grade No.60 (0.000 .017 (0.8900 .0374) Piston Pin EM Unit: mm (in) Grade* Dimension Piston pin outer diameter Grade No.1. 5 48.50.0001 .1.0236) 0.7874 .0.50 (0.001 (1. 0 48.1.48.8902 .0118) Grade No. A 48.0.20 .002 (1.20.8899 .001 .8900 .8901) Grade No.30 (0.0256) Oil ring (rail ring) 0.0.0007) *: Always check with the Parts Department for the latest parts information.009 (1.0002 . 6 48.0002) D Connecting rod bushing oil clearance Standard 0. 2 48.94)] Limit 0.94)] Limit 0.143.1.8902) Grade No.0.48.1. B 48.005 .0138) Side clearance Limit 0.8900) Connecting rod big end diameter Grade No.48.007 (1.000 .48.0059) G Torsion [per 100 (3.0.1.0079 .006 (0.00 . 9 48.011 (1. 0 19. 1 20.8902) Grade No.1.8898) Grade No.0213) A End gap 2nd 0.995 .0122) 0.634) Bend [per 100 (3.8898) I Grade No.005 .8898 . 1 19.0083 . 2: After installing in connecting rod M CRANKSHAFT Unit: mm (in) N O P SEM645 SBIA0535E Center distance “r” 49.0.0126 .8898 .0.010 .47 (0.007 .31 (0.0.0.012 .002 .10 (5.005 (1.012 (0.7872) C Grade No.011 .989 .009 .48.8902 .1. 1 48. C 48.20.19.7870 .15 (0.008 .1.006 (0.012 (1.20.48.0.9669 .04 (1.48.5.48.8899 .8901 .8903) 1 : Always check with the Parts Department for the latest parts information.004 (1. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] Top 0.0185) 0.7874) Piston to piston pin oil clearance Standard 0.006 (1.995 (0. 4 48.008 (1.7876 .8900) Grade No.630 .9701) Revision: August 2014 EM-115 2015 Frontier NAM .7872 .96 .48.1.003 (1.95 (0. 3 48. 0 20. E CONNECTING ROD Unit: mm (in) Items Grade1 F Center distance 143.48.8901 .002 .

961 .44.54.1.7702 .1.978 .44.970 .971 .44.2.54. “DP” Grade No.2.969 .974 .971 (2.7701) Grade No.1.1637) Grade No.1645) Grade No.958 .54.967 (2.1637) Grade No. T 54.1637) Grade No.1643) Grade No.974 .44.7701) Grade No.54.977 .963 (2. J 54.2.0. E 54. K 54.7704 .1. G 54.54.1. A 44.05 (0.7702) Grade No.968 .975 . 7 54.963 .965 . U 44.969 .44.54.2.7705 .54.1642) Grade No.1642 .7700 .44. H 54.961 (2.1639) Grade No.962 . T 44.969 (1.1.960 .1640) Grade No.7703) Pin journal diameter grade.977 (2.0001) Runout [TIR*] Limit 0.966 .965 (1. N 44.1640 . 4 54. M 54. R 54.54.1645 .1.1.960 (2.44.2.958 (2.1.964 (1.973 .978 (2.54.2.1636 . L 54. Y 54.54.7704) Grade No.957 (2.955 (2.963 (1.976 (2.1643 .7703 . “Dm” Grade No. C 54.970 (1.1638 .54.970 (2.964 .44. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] Out-of-round (Difference between “X” and “Y”) Limit 0.956 (1.1642 .961 (1.44.965 .960 . R 44.973 (1.2.1640) Grade No.956 (2.30 (0.0025 (0. L 44.2.974 (2.1638) Grade No.54.959 .7702 .2.44.2. K 44.1642) Grade No.7706 .44.7705) Grade No.7701 .7702 .54.0025 (0.966 (1.1638) Grade No.968 .1639 .972 (1.2.1641) Main journal diameter grade.7706) Grade No.958 .1637 .973 (2. F 44. M 44.7702) Grade No.1.1641) Grade No.1643) Grade No.967 .957 (1. H 44. B 44.962 (2.962 .7705) Grade No.1636) Grade No.1638 .7705 .2.7701 . A 54.970 .7699) Grade No. X 54.960 (1.959 (1.1643 .1641 .969 (2.2.44.2.2.7700) Grade No.1642 . N 54.972 .1639 .7704 .964 . U 54. B 54. D 44.2.1.1644) Grade No. E 44.966 (2.972 (2.957 .7700 .1637 .54.1639) Grade No.973 . W 54.7703 .54.44. V 54.1644) Grade No.7703) Grade No.54.26 (0.1644 .1636) * : Total indicator reading MAIN BEARING Revision: August 2014 EM-116 2015 Frontier NAM .959 (2.1644 . P 44.7705) Grade No.7704 .1641 .0118) Grade Dimension Grade No.1641) Grade No.7702) Grade No.1. G 44.1641 . F 54. S 54.967 (1.2.1639) Grade No.0.972 .958 (1.54.2.976 .975 (2.971 .1.963 .54.44.1.957 .2.54.962 (1.7705 .1.54.54. J 44.44.1.1640 . S 44.968 (2.7700 .44.966 .956 .54.2. P 54.1639 .7700) Grade No.7704) Grade No.7704) Grade No.7706 .2.2.965 (2.968 (1.1.1642) Grade No. D 54.1644 .54. C 44.0039 .964 (2.971 (1.959 .1644) Grade No.0020) Standard 0.2.54.2.1.0001) Taper (Difference between “A” and “B”) Limit 0.979 .10 .967 .961 .44.44.1645 .0102) Crankshaft end play Limit 0.7700) Grade No.1637 .

0778 .994 .0777 .973 .0781 .0.1.979 (0.982 .028 .991 .0779 .0.0780) Green 23 J LWR 1.25 (0.041 .0783) Blue for upper and lower bearings.0785) Purple 7 1.976 .0783 .1.988 .0.004) CONNECTING ROD BEARING Revision: August 2014 EM-117 2015 Frontier NAM .0786) White H UPR 1.0778) Black 01 LWR 1.982 (0.997 (0.0829 .0.991 .0.0.0781 .0.1.973 .1.0784 .979 (0.0781) Yellow Grade and color are the same 4 1.1.985 (0.994 (0.1.982 (0.0785) Purple UPR 1. 2 and 4 0.1.0098) 2.988 (0.0783) Blue K UPR 1.0.0779 .994 (0.1.991 .982 (0.0.0785 .982 .994 . N Undersize Unit: mm (in) Item Thickness Main journal diameter O US 0.988 .988 (0.976 (0.042 (0.0.1.976 (0.0786) White *: Always check with the Parts Department for the latest parts information.0783 . 1.0778) Black 1 1.0784) Pink G 6 1. 34 LWR 1.0780) Green UPR 1.0.0022) Limit 0. 3 and 5 0.106 .0783 .979 .0784) Pink 56 LWR 1. 5 1.1.0784) Pink L UPR 1.976 .991 (0.0011 .0780 .0784 .988 (0.994 (0.0016 .2.0.114 (0.1.1.0778 .0781) Yellow Grade and color are different UPR 1.056 (0.1.0.991 (0.0781) Yellow for upper and lower bearings.0.979 .1.0.0.1.0832) Grind so that bearing clearance is the specified value.0779) Brown I 12 LWR 1. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] Unit: mm (in) A EM C D SEM685D Grade number* Thickness Identification color Remarks E 0 1.0.0.991 (0.0783) Blue 45 LWR 1.0781 .0785 .0.976 .0785) Purple M 67 LWR 1.1.979 .985 (0.985 .0.0.1.1 (0.985 . Bearing Oil Clearance Unit: mm (in) P No.1.0779) Brown 2 1.982 .0.0780 .0777 .985 (0.1.0780) Green F 3 1.1.997 (0.0.988 .0779 .1.0784 .985 .0.0778 .1.0780 .0.0.0017) Standard Main bearing oil clearance No.0779) Brown UPR 1.979 (0.0.

0098) 1.0588 .0.1.496 .0590 .045 (0.0.10 (0.0594) Blue *: Always check with the Parts Department for the latest parts information.0591 .0014 .0643) Grind so that bearing clearance is the specified value.0589 .0593) Yellow 4 1.0. Bearing Oil Clearance Unit: mm (in) Standard 0.496 (0.505 .502 (0.1.505 (0.1.508 (00.0.493 .499 (0.0.632 (0.0589) Black 1 1.0639 .0039) Revision: August 2014 EM-118 2015 Frontier NAM .0018) Connecting rod bearing oil clearance Limit 0.1.624 .25 (0.1.0.0.502 .0.499 .035 . SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE] Grade number* Thickness mm (in) Identification color 0 1.1.0590) Brown 2 1.593 .0591) Green 3 1. Undersize Unit: mm (in) Item Thickness Crank pin journal diameter US 0.

and so on. as a basic rule. This system includes seat belt switch inputs and dual stage front air bag modules. see the SR section. Power tools may be used in the step. avoid N forceful or uninstructed operations. can lead to personal injury caused by unintentional activation of the system. and may only deploy one front air bag. Heavy vibration could activate the sensor(s) and deploy the air bag(s). M Precaution for Removal and Disassembly INFOID:0000000010709689 • When instructed to use special service tools. D Information necessary to service the system safely is included in the SR and SB section of this Service Man- ual. 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 performed by an authorized NISSAN/INFINITI dealer. possibly causing serious injury. including incorrect removal and installation of the SRS. Precaution for Drain Engine Coolant INFOID:0000000010709687 K Drain engine coolant when engine is cooled. to seal out foreign materials. do exactly as specified. • Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly. PRECAUTIONS < PRECAUTION > [VQ40DE] PRECAUTION A PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM PRE-TENSIONER" INFOID:0000000010709686 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”. plug openings to stop fuel leakage. and replace if necessary. if necessary. helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. • After disconnecting pipes. depending on the severity of a collision and whether the front occupants are belted or unbelted. • Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this G Service Manual. • Exercise maximum care to avoid damage to mating or sliding surfaces. thoroughly inspect parts. The SRS system uses the seat belt switches to determine the front air bag deployment. disconnect the J battery and wait at least three minutes before performing any service. always switch the Ignition OFF. start with the one furthest outside. Repair and Replacement INFOID:0000000010709690 Before repairing or replacing. make sure no fire or spark producing items are in the work area. • Cover openings of engine system with tape or equivalent. For removal of Spiral Cable and Air Bag Module. PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS H WARNING: • When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni- tion ON or engine running. Inspect new replacement parts in the same way. DO NOT use air or electric power tools or strike near the sensor(s) with a I hammer. Always be careful to work safely. P Precaution for Inspection. use the specified tools. • When using air or electric power tools or hammers. F • Improper maintenance. then the one diagonally opposite. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har- ness connectors. If the order of loosening is specified. used along C with a front seat belt. • Release fuel pressure before disconnecting and disassembly. Revision: August 2014 EM-119 2015 Frontier NAM . WARNING: E • To avoid rendering the SRS inoperative. O • When loosening nuts and bolts. Precaution for Disconnecting Fuel Piping INFOID:0000000010709688 L • Before starting work.

2. • When tightening nuts and bolts. Carefully check engine oil or engine coolant passages for any restriction and blockage. bolts. and air-blow each part. and exhaust gasses for leakage. do exactly as specified. and bolt holes. oil sliding surfaces well. Completely remove foreign materials such as cloth lint or dust. packing. Remove the old liquid gasket adhering to the gasket application surface and the mating surface using suitable tool. as a basic rule. lightly tap to slide it (2). Thoroughly clean the mating surfaces and remove adhering moisture. • Ensure thread and seat surfaces are clean and coated with engine oil. Before assembly. WBIA0566E LIQUID GASKET APPLICATION PROCEDURE 1. PBIC0003E Revision: August 2014 EM-120 2015 Frontier NAM .Cylinder head bolts . clean. equally tighten in several different steps starting with the ones in center. • Thoroughly wash. • Tap the seal cutter to insert it (1). oil seal or O-ring. • Avoid damaging sliding or mating surfaces. grease and foreign material. fuel. PRECAUTIONS < PRECAUTION > [VQ40DE] Precaution for Assembly and Installation INFOID:0000000010709691 • Use torque wrench to tighten bolts or nuts to specification. • Replace with new gasket. • Remove the liquid gasket completely from the groove of the liquid gasket application surface. • In areas where the Tool is difficult to use. start engine and increase engine speed to check engine coolant.Crankshaft pulley bolt (No angle wrench is required as bolt flange is provided with notches for angle tighten- ing) • Do not use a torque value for final tightening. • After repairing.Lower cylinder block bolts . separate the mating surface and remove the old liquid gasket using Tool. • Release air within route when refilling after draining engine coolant. Then make sure that there are no leaks at fuel line connections. Tool number : KV10111100 (J-37228) CAUTION: Do not damage the mating surfaces. Precaution for Liquid Gasket INFOID:0000000010709693 REMOVAL OF LIQUID GASKET • After removing the bolts and nuts. • The torque value for these parts are for a preliminary step. • Before starting engine. Parts Requiring Angle Tightening INFOID:0000000010709692 • For the final tightening of the following engine parts use Tool: Tool number : KV10112100 (BT-8653-A) . apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). engine oil.Connecting rod cap bolts . then ones on inside and outside diagonally in this order. If the order of tightening is specified.

"Recommended Chemical Products and Sealants". • Wait 30 minutes or more after installation before refilling the G engine with oil or coolant. 4. Also apply to the outside edge of the bolt holes when specified in the procedure. observe them. PRECAUTIONS < PRECAUTION > [VQ40DE] 3. • Within five minutes of liquid gasket application. apply the liquid gasket to the groove. SEM159F CAUTION: If there are more specific instructions in the procedures contained in this manual conerning liquid H gasket application. I J K L M N O P Revision: August 2014 EM-121 2015 Frontier NAM . EM C WBIA0567E D • If there is a groove for the liquid gasket application. Attach the liquid gasket tube to the suitable tool. F • If the liquid gasket protrudes. install the mat- ing component. • Normally apply the liquid gasket on the inside edge of the bolt E holes. Apply the liquid gasket without breaks to the specified location with the specified dimensions. Use Genuine RTV Silicone Sealant or equivalent. • Do not retighten after the installation. Refer to A GI-21. wipe it off immediately.

front and (J-37228) rear timing chain case. but Part (2) is not so. Seal cutter NT046 KV991J0050 Loosening or tightening air fuel ratio A/F sen- (J-44626) sor Air fuel sensor Socket a: 22 mm (0. ST05012000 ( — ) Base NT042 16441 6N210 Removing fuel tube quick connectors in en- (J-45488) gine room. PREPARATION < PREPARATION > [VQ40DE] PREPARATION PREPARATION Special Service Tool INFOID:0000000010709694 The actual shape of the tools may differ from those tools illustrated here. Tool number Description (TechMate No.KV10109220 ( — ) Adapter PBIC1650E Revision: August 2014 EM-122 2015 Frontier NAM . etc. Quick connector release PBIC0198E KV10111100 Removing oil pan (lower and upper).) Tool name ST0501S000 Disassembling and assembling engine ( — ) Engine stand assembly 1. KV10115900 (J-26336-20) Attachment 2.87 in) NT636 KV10116200 Disassembling valve mechanism (J-26336-B) Part (1) is a component of KV10116200 (J- Valve spring compressor 26336-B). 1. ST05011000 ( — ) Engine stand 2.87 in) LBIA0444E KV10114400 Loosening or tightening heated oxygen sen- (J-38365) sor 1 Heated oxygen sensor wrench a: 22 mm (0.

(J-49815) N 2. PREPARATION < PREPARATION > [VQ40DE] Tool number Description (TechMate No. (J-8092) Seal installer and driver handle O AWBIA0862ZZ P Revision: August 2014 EM-123 2015 Frontier NAM . main bear- (BT-8653-A) ing cap and connecting rod cap I Angle wrench J AWBIA1043ZZ K ST16610001 Removing pilot converter (J-23907) Pilot bushing puller L M NT045 — Installing rear main seal 1.) A Tool name KV10107902 Replacing valve oil seal (J-38959) EM Valve oil seal puller C NT011 — Installing valve oil seal D (J-39386) Valve oil seal drift E NT024 F EM0347000 Installing piston assembly into cylinder bore (J-8037) Piston ring compressor G H NT044 KV10112100 Tightening bolts for cylinder head.

55 in) 1. screws and bolts ( — ) Power tool PIIB1407E — Pressing the tube of liquid gasket ( — ) Tube presser NT052 KV991J0100 Removing and installing flywheel (J-46531) Size: T55 Socket PBIC1113E Revision: August 2014 EM-124 2015 Frontier NAM . PREPARATION < PREPARATION > [VQ40DE] Tool number Description (TechMate No.) Tool name — Installing exhaust manifold nuts ( — ) a: 14 mm (0. Crowfoot 2. pressed position sioner pins ALBIA0678ZZ Commercial Service Tool INFOID:0000000010709695 Tool number Description (TechMate No. Torque wrench S-NT360 — Loosening nuts.) Tool name KV11105210 Removing and installing crankshaft pulley (J-44716) Ring gear stopper ALBIA0523ZZ — Installing secondary timing chain tensioner (J-50246) shoes and locking chain tensioners in com- Tensioner shoe installer and chain ten.

4014 in) dia.0.236 in) dia. d2: 10.10. b: 12 (0.] for tita- nia heated oxygen sensor AEM488 Revision: August 2014 EM-125 2015 Frontier NAM . O NT016 — Reconditioning the exhaust system threads P (J-43897-18) before installing a new heated oxygen sensor (J-43897-12) (Use with anti-seize lubricant shown below. L M NT015 — (1): Reaming valve guide inner hole ( — ) (2): Reaming hole for oversize valve guide N Valve guide reamer Intake and Exhaust: d1: 6.196 mm (0.47 in) dia.) Oxygen sensor thread cleaner a: J-43897-18 [18 mm (0.] for zir- conia heated oxygen sensor b: J-43897-12 [12 mm (0.) A Tool name — Removing and installing spark plug ( — ) EM Spark plug wrench C NT047 — Loosening and tightening cylinder head bolt.51) dia.47) E c: 10 (0. PREPARATION < PREPARATION > [VQ40DE] Tool number Description (TechMate No. D (J-24239-01) and used with angle wrench [SST: Cylinder head bolt wrench KV10112100 (BT8653-A)] a: 13 (0.175 .217 in) dia.374 in) dia.71 in) dia.0 mm (0.5 mm (0. b: 5.39) Unit: mm (in) NT583 F — Finishing valve seat dimensions ( — ) Valve seat cutter set G H NT048 — Removing and installing piston ring ( — ) I Piston ring expander J NT030 K — Removing and installing valve guide ( — ) Intake and Exhaust: Valve guide drift a: 9.5 mm (0.4006 .

PREPARATION < PREPARATION > [VQ40DE] Tool number Description (TechMate No.) Tool name — Lubricating oxygen sensor thread cleaning ( — ) tool when reconditioning exhaust system Anti-seize lubricant (Permatex 133AR threads or equivalent meeting MIL specifica- tion MIL-A-907) AEM489 — Removing and installing engine ( — ) Manual lift table caddy ZZA1210D Revision: August 2014 EM-126 2015 Frontier NAM .

Locate the area where noise occurs. VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting . Revision: August 2014 EM-127 2015 Frontier NAM . VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING < SYSTEM DESCRIPTION > [VQ40DE] SYSTEM DESCRIPTION A NOISE. NOISE.Engine Noise INFOID:0000000010709696 EM C D E F G H I J K L M N O P PBIC2873E Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000010709697 1.

VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING < SYSTEM DESCRIPTION > [VQ40DE] 2. Connecting rod bushing Oil pan ing rod oil clearance EM-230 Knock A B C B B B bearing Connecting rod bearing EM-230 noise oil clearance Main bearing oil clear- Main bear. EM-230 Knock A B — A B C ance ing noise EM-230 Crankshaft runout Timing Front of Timing chain cracks chain and engine Tapping or and wear EM-176 A A — B B B chain ten- Timing ticking Timing chain tensioner EM-184 sioner chain case operation noise Drive belts Squeak- (Sticking ing or fizz. noise ence page idling racing driving up up ing Top of en. 3. Specify the operating condition of engine. Check specified noise source. Confirm the type of noise. repair or replace these parts. NOISE. 4. start. If necessary. Operating condition of engine Location Type of Before After When Source of Refer- When When While Check item of noise noise warm. A B — B — C Drive belts deflection or slip- ing EM-129 ping) Front of Drive belts Idler pulley bearing op- engine Creaking A B A B A B (Slipping) eration Water Squall A B — B A B pump Water pump operation CO-50 Creak noise Rattle — — A — — — VTC VTC lock pin clearance EM-193 A: Closely related B: Related C: Sometimes related —: Not related Revision: August 2014 EM-128 2015 Frontier NAM . Ticking or Tappet C A — A B — Valve clearance EM-134 gine clicking noise Rocker cover Camshaft Camshaft runout EM-193 Cylinder Rattle C A — A B C bearing Camshaft journal oil EM-193 head noise clearance Piston to piston pin oil Slap or Piston pin clearance EM-230 — A — B B — knock noise Connecting rod bushing EM-230 oil clearance Piston to cylinder bore Crank. warm. Piston ring side clear- Slap or Piston EM-230 ley A — — B B A ance rap slap noise EM-230 Cylinder Piston ring end gap EM-230 block Connecting rod bend (Side of and torsion engine) Connect. clearance EM-230 shaft pul.

1. Remove air duct and resonator assembly. damage or cracks. Drive belt tensioner I Checking Drive Belts INFOID:0000000010709699 WARNING: J Be sure to perform when the engine is stopped. 3. Drive belt 2. Cooling fan pulley Idler pulley (without A/C) 7. "Removal and Installation". Remove air duct and resonator assembly when inspecting drive belt. DRIVE BELTS < PERIODIC MAINTENANCE > [VQ40DE] PERIODIC MAINTENANCE A DRIVE BELTS Exploded View INFOID:0000000010709698 EM C D E F G LBIA0427E 1. The drive belt tension is automatically adjusted by the drive belt auto-tensioner. Revision: August 2014 EM-129 2015 Frontier NAM . Generator pulley A/C compressor (with A/C) H 4. "Removal and Installation". If the indicator is out of allowable working range or drive belt is damaged. Refer to EM-141. replace the drive belt. Idler pulley 8. Refer to EM-129. M N AWBIA0723ZZ Adjustment INFOID:0000000010709700 O There is no manual drive belt tension adjustment. Crankshaft pulley 5. Removal and Installation INFOID:0000000010709701 P REMOVAL 1. 6. K 2. Visually check entire belt for wear. Refer to EM-141. Make sure that the auto-tensioner indicator is within the allow- able working range (A) as shown. "Removal and Installation". L 4. Power steering oil pump pulley 3.

"Removal and Installation". CAUTION: If there is damage greater than peeled paint. WARNING: Avoid placing hand in a location where pinching may occur if the tool accidentally comes off. Remove the drive belt. Remove drive belt. CAUTION: Make sure belt is securely installed around all pulleys. 3. Idler pulley 2. Refer to EM-141. using suitable tool. Drive belt auto-tensioner REMOVAL 1. Drive Belt Auto-Tensioner and Idler Pulley INFOID:0000000010709702 AWBIA0861GB 1. Rotate the drive belt auto-tensioner in the direction of arrow (loosening direction of tensioner) as shown. Revision: August 2014 EM-130 2015 Frontier NAM . LBIA0428E INSTALLATION Installation is in the reverse order of removal. 3. DRIVE BELTS < PERIODIC MAINTENANCE > [VQ40DE] 2. Remove air duct and resonator assembly. "Removal and Installation". replace drive belt auto-tensioner. 2. Refer to EM-129. INSTALLATION Installation is in the reverse order of removal. Remove drive belt auto-tensioner and idler pulley.

Disconnect mass air flow sensor. Unhook clips. 4. and lift air cleaner case (upper). Air duct and resonator assembly H Front Removal and Installation INFOID:0000000010709704 I REMOVAL 1. Mass air flow sensor 5. L M N O P Revision: August 2014 EM-131 2015 Frontier NAM . Air cleaner filter 3. Air cleaner case (upper) 4. J 2. K INSTALLATION Installation is in the reverse order of removal. Remove air cleaner filter. 3. Disconnect air duct and resonator assembly from the air cleaner case (upper). Air cleaner case (lower) 2. AIR CLEANER FILTER < PERIODIC MAINTENANCE > [VQ40DE] AIR CLEANER FILTER A Exploded View INFOID:0000000010709703 EM C D E F G AWBIA1521ZZ 1.

Remove spark plug using suitable tool. CAUTION: Do not drop or shock it. Spark plug Removal and Installation INFOID:0000000010709706 REMOVAL 1. spark plug cleaner may be used. SMA773C • If the spark plug tip is covered with carbon. Revision: August 2014 EM-132 2015 Frontier NAM . SEM294A INSPECTION AFTER REMOVAL • Do not use a wire brush for cleaning. Remove ignition coil. Refer to EM-157. SPARK PLUG < PERIODIC MAINTENANCE > [VQ40DE] SPARK PLUG Exploded View INFOID:0000000010709705 PBIC2901E 1. 2. "Removal and Installation". Ignition coil 2.

SPARK PLUG
< PERIODIC MAINTENANCE > [VQ40DE]

Cleaner air pressure : Less than 588 kPa (6 kg/cm2, 85 psi) A
Cleaning time : Less than 20 seconds
• Checking and adjusting spark plug gap is not required between
EM
change intervals.

C

D

SMA806CA
E

INSTALLATION
Installation is in the reverse order of removal. F
CAUTION:
Do not drop or shock the spark plug.
G
Make NGK
Standard type* DILFR5A-11
Gap (nominal) 1.1 mm (0.043 in) H
*: Always check with the Parts Department for the latest parts information.

I

J

K

L

M

N

O

P

Revision: August 2014 EM-133 2015 Frontier NAM

CAMSHAFT VALVE CLEARANCE
< PERIODIC MAINTENANCE > [VQ40DE]
CAMSHAFT VALVE CLEARANCE
Valve Clearance INFOID:0000000010709707

INSPECTION
NOTE:
Perform the following inspection after removal, installation or replacement of camshaft or valve-related parts,
or if there are unusual engine conditions due to changes in valve clearance over time (starting, idling, and/or
noise).
1. Remove the engine room cover using power tool. Refer to EM-140, "Removal and Installation".
2. Remove the air cleaner and air duct assembly. Refer to EM-141, "Removal and Installation".
3. Remove rocker covers (RH and LH banks). Refer to EM-158, "Removal and Installation".
4. Measure the valve clearance as follows:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley clockwise to align timing mark (A)
(grooved line without color) with timing indicator (B).

AWBIA0719ZZ

• Make sure that intake and exhaust cam noses on No. 1 cylin-
der (engine front side of RH bank) are located as shown.
• If not, rotate crankshaft one revolution (360°) and align as
shown.

SEM418G

b. Use feeler gauge, measure the clearance between valve lifter
and camshaft.

SEM139D

Valve Clearance
Unit: mm (in)

Cold 1 (reference data) Hot 2 (reference data)
Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)
1
: Approximately 20°C (68°F)

Revision: August 2014 EM-134 2015 Frontier NAM

CAMSHAFT VALVE CLEARANCE
< PERIODIC MAINTENANCE > [VQ40DE]
2
: Approximately 80°C (176°F)
• Measure the valve clearances at locations marked “×” as A
shown in the table below (locations indicated in the illustration)
with feeler gauge.
• No. 1 cylinder at compression TDC EM
Measuring position (RH bank) No. 1 CYL. No. 3 CYL. No. 5 CYL.

No. 1 cylinder at EXH ×
C
compression TDC INT ×
Measuring position (LH bank) No. 2 CYL. No. 4 CYL. No. 6 CYL.

No. 1 cylinder at INT × D
compression TDC EXH ×

E

F

G

PBIC2054E

c. Rotate crankshaft by 240° clockwise (when viewed from engine H
front) to align No. 3 cylinder at TDC of its compression stroke.
NOTE:
Crankshaft pulley bolt flange has a stamped line every 60°. They I
can be used as a guide to rotation angle.

J

PBIC2916E
K

• Measure the valve clearances at locations marked “×” as
shown in the table below (locations indicated in the illustration) L
with feeler gauge.
• No. 3 cylinder at compression TDC
M
Measuring position (RH bank) No. 1 CYL. No. 3 CYL. No. 5 CYL.

No. 3 cylinder at EXH ×
compression TDC INT × N
Measuring position (LH bank) No. 2 CYL. No. 4 CYL. No. 6 CYL.

No. 3 cylinder at INT ×
compression TDC O
EXH ×

P

PBIC2055E

Revision: August 2014 EM-135 2015 Frontier NAM

CAMSHAFT VALVE CLEARANCE
< PERIODIC MAINTENANCE > [VQ40DE]
d. Rotate crankshaft by 240° clockwise (when viewed from engine
front) to align No. 5 cylinder at TDC of compression stroke.

PBIC2916E

• Measure the valve clearances at locations marked “×” as
shown in the table below (locations indicated in the illustration)
with feeler gauge.
• No. 5 cylinder at compression TDC

Measuring position (RH bank) No. 1 CYL. No. 3 CYL. No. 5 CYL.

No. 5 cylinder at EXH ×
compression TDC INT ×
Measuring position (LH bank) No. 2 CYL. No. 4 CYL. No. 6 CYL.

No. 5 cylinder at INT ×
compression TDC EXH ×

PBIC2056E

5. For the measured value out of the standard, perform adjustment.
ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Measure the valve clearance.
2. Remove camshaft. Refer to EM-193, "Removal and Installation".
3. Remove valve lifters at the locations that are out of the standard.
4. Measure the center thickness of removed valve lifters with
micrometer.

KBIA0057E

5. Use the equation below to calculate valve lifter thickness for replacement.

Revision: August 2014 EM-136 2015 Frontier NAM

CAMSHAFT VALVE CLEARANCE
< PERIODIC MAINTENANCE > [VQ40DE]

Valve lifter thickness calculation: t = t1+ (C1– C2) A
t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
EM
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.30 mm (0.012 in)* C
Exhaust : 0.33 mm (0.013 in)*
*: Approximately 20°C (68°F)
D
• Thickness of new valve lifter can be identified by stamp marks
on the reverse side (inside the cylinder).

E

F

G
KBIA0119E

Intake
Stamp mark Thickness
H
788U 7.88 mm (0.3102 in)
790U 7.90 mm (0.3110 in)
· · I
· ·
840U 8.40 mm (0.3307 in)
J
Available thickness of valve lifter: 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) in steps of
0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-248, "Standard and Limit".
Exhaust K
Stamp mark Thickness
N788 7.88 mm (0.3102 in)
N790 7.90 mm (0.3110 in) L
· ·
· ·
M
N836 8.36 mm (0.3291 in)
Available thickness of valve lifter: 25 sizes with range 7.88 to 8.36 mm (0.3102 to 0.3291 in) in steps of
0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-248, "Standard and Limit". N
CAUTION:
Install identification letter at the end and top, “U” and “N”, at each of proper positions. (Be care-
ful of mis-installation between intake and exhaust.)
6. Install selected valve lifter. O
7. Install camshaft. Refer to EM-193, "Removal and Installation".
8. Manually turn crankshaft pulley a few turns.
P
9. Make sure that the valve clearances for cold engine are within the specifications by referring to the speci-
fied values.
10. Installation of the remaining components is in the reverse order of removal.
11. Start the engine, and check for unusual noise and vibration.

Revision: August 2014 EM-137 2015 Frontier NAM

79 in) in diameter. • If the engine speed is out of the specified range check the battery and recharge as necessary. Refer to EM-132. it may be caught by cylinder head during removal. Warm up engine thoroughly. Disconnect fuel pump fuse to avoid fuel injection during mea- surement. 14) / 300 CAUTION: Always use a fully charged battery to obtain specified engine speed. Refer to EC-968. 3. BBIA0534E 4. "Removal and Installation". Install compression tester with adapter onto spark plug hole. COMPRESSION PRESSURE < PERIODIC MAINTENANCE > [VQ40DE] COMPRESSION PRESSURE Compression Pressure INFOID:0000000010709708 CHECKING COMPRESSION PRESSURE 1. 142) / 300 98 (1. Release fuel pressure. 185) / 300 981 (10.0. 5. Remove spark plug from each cylinder. Remove intake manifold collector. 7. When the gauge pointer stabilizes.0. 2. Refer to EM-142. 6. read the compression pressure and engine rpm. Perform these steps to check each cylinder. Check the engine speed again with the battery properly charged. Turn ignition switch to “START” for cranking. psi) /rpm Standard Minimum Differential limit between cylinders 1. Connect engine tachometer (not required in use of CONSULT). SBIA0533E 8. Revision: August 2014 EM-138 2015 Frontier NAM . PBIC0900E • Use compression gauge whose pick up end inserted to spark plug hole is smaller than 20 mm (0.275 (13. "Fuel Pressure Check". "Removal and Installation". Other- wise.0. Compression pressure: Unit: kPa (kg/cm2.

pour a small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. Perform trouble diagnosis. check the valve clearances and parts associ. cylinder head gasket). "Description". valve seat.If the compression pressure remains at a low level despite the addition of engine oil.C ated with the combustion chamber (valve. • If the compression pressure is below the minimum value. cylinder bore. Check the valves for damage. cylinder head. After repairing as necessary. 11. E F G H I J K L M N O P Revision: August 2014 EM-139 2015 Frontier NAM . .If the added engine oil improves the compression. A . piston. If DTC appears. the valves may be EM malfunctioning. Start the engine. and confirm that it runs smoothly. Install the components in the reverse order of removal. cylinder head gaskets may be leaking. Refer to EC-609. D 10. 9. erase it. Check the piston rings and replace if necessary . COMPRESSION PRESSURE < PERIODIC MAINTENANCE > [VQ40DE] • If some cylinders have low compression pressure. measure the compression pressure again.If two adjacent cylinders have low compression pressure and their compression remains low even after the addition of engine oil. piston ring. Replace the valve or valve seat accordingly. piston rings may be worn out or damaged.

Lift up on engine cover firmly to dislodge snap fit mounts. 2. Remove the engine room cover bolts using power tool. REMOVAL 1. Revision: August 2014 EM-140 2015 Frontier NAM . ENGINE ROOM COVER < REMOVAL AND INSTALLATION > [VQ40DE] REMOVAL AND INSTALLATION ENGINE ROOM COVER Removal and Installation INFOID:0000000010709709 CAUTION: Do not damage or scratch cover when installing or removing. WBIA0622E INSTALLATION Installation is in the reverse order of removal.

• Do not touch its sensor. L 6. Refer to EM-140. Disconnect the harness connector from mass air flow sensor. O INSTALLATION Installation is in the reverse order of removal. REMOVAL J 1. AIR CLEANER AND AIR DUCT < REMOVAL AND INSTALLATION > [VQ40DE] AIR CLEANER AND AIR DUCT A Exploded View INFOID:0000000010709710 EM C D E F G AWBIA1521ZZ 1. CAUTION: Handle mass air flow sensor with care. • Do not disassemble it. Remove the air duct and resonator assembly and air cleaner case (upper). Air cleaner filter 3. If necessary remove the mass air flow sensor from the air cleaner case (upper). Air cleaner case (lower) 2. 5. K 3. Air duct and resonator assembly H Front Removal and Installation INFOID:0000000010709711 I NOTE: Add marks as necessary for easier installation. Air cleaner case (upper) 4. • If anything found. "Removal and Installation". Disconnect crankcase ventilation hose. replace air duct and resonator assembly. Mass air flow sensor 5. Remove air cleaner filter and air cleaner case (lower). N INSPECTION AFTER REMOVAL Inspect air duct and resonator assembly for cracks or tears. P Revision: August 2014 EM-141 2015 Frontier NAM . 4. Remove the engine room cover using power tool. M • Do not shock it. 2.

3. Water hose 6. To cylinder head (RH bank) Removal and Installation INFOID:0000000010709713 NOTE: When removing components such as hoses. Vacuum hose 4. PCV hose 17. To power valve c. To intake manifold collector b. "Removal and Installation".. "Changing Engine Coolant". EVAP hose 11. Partially drain engine coolant. Remove air duct and resonator assembly. Disconnect water hoses from electric throttle control actuator. WARNING: To avoid the danger of being scalded. VIAS control solenoid valve 3. Refer to EM-140. Gasket 14. Connector 18. b. Intake manifold collector 15. Revision: August 2014 EM-142 2015 Frontier NAM . "Removal and Installation". INTAKE MANIFOLD COLLECTOR < REMOVAL AND INSTALLATION > [VQ40DE] INTAKE MANIFOLD COLLECTOR Exploded View INFOID:0000000010709712 WBIA0731E 1. 2. Water hose 8. etc. Gasket solenoid valve 13. cap or plug openings to prevent fluid from spill- ing. Electric throttle control actuator 7. Vacuum tank 2. do not drain engine coolant when engine is hot. REMOVAL 1. Intake manifold collector support 5. CAUTION: • Perform when engine is cold. EVAP canister purge volume control 12. • Do not spill engine coolant on drive belt. Clip 16. To throttle body d. Refer to CO-40. PCV hose a. Bracket 10. Remove electric throttle control actuator as follows: a. Remove engine room cover using power tool. EVAP hose 9. Refer to EM-141. tubes/lines.

and remove intake manifold collector. Disconnect EVAP hoses and harness connector from EVAP canister purge volume control solenoid valve. Remove the following parts: • Vacuum hose (to brake booster) E • PCV hose 5. K CAUTION: Cover engine openings to avoid entry of foreign materials. d. 9. Loosen nuts and bolts in reverse order as shown with power tool. Note the following: Intake Manifold Collector • If stud bolts were removed from intake manifold. INTAKE MANIFOLD COLLECTOR < REMOVAL AND INSTALLATION > [VQ40DE] c. 61 in-lb) P Revision: August 2014 EM-143 2015 Frontier NAM . Remove VIAS control solenoid valve and vacuum tank.7 kg-m. 8. F G H PBIC2876E I 6. install them and tighten to the specified torque. Disconnect harness connector. J • Add mating marks as necessary for easier installation. Remove EVAP canister purge volume control solenoid valve. 7. A CAUTION: • Handle carefully to avoid any shock to electric throttle control actuator.9 N·m (0. C PBIC2875E D 4. Loosen bolts in reverse order as shown. L M PBIC2877E INSTALLATION N Installation is in the reverse order of removal. O Stud bolts : 6. EM • Do not disassemble. Loosen bolts in reverse order as shown to remove intake mani- fold collector support.

PBIC2876E Electric Throttle Control Actuator • Tighten bolts in numerical order as shown. INTAKE MANIFOLD COLLECTOR < REMOVAL AND INSTALLATION > [VQ40DE] • Tighten nuts and bolts in numerical order as shown. PBIC2875E Revision: August 2014 EM-144 2015 Frontier NAM . • Perform the “Throttle Valve Closed Position Learning” when har- ness connector of electric throttle control actuator is disconnected. Refer to EC-593.0 N·m (1. 8 ft-lb) bolts and nuts PBIC2877E Intake Manifold Collector Support Tighten the intake manifold collector support bolts to specification in the order as shown to install the intake manifold collector support. "Idle Air Volume Learning". • Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when electric throttle control actuator is replaced.1 kg-m. Intake manifold collector : 11. Refer to EC-593. "Throttle Valve Closed Position Learning".

Loosen nuts and bolts with power tool in reverse order as shown K to remove intake manifold. L M PBIC2879E N 4. Remove intake manifold collector. "Removal and Installation". tubes/lines. Intake manifold 2. INSPECTION AFTER REMOVAL P Surface Distortion Revision: August 2014 EM-145 2015 Frontier NAM . Remove fuel tube and fuel injector assembly. INTAKE MANIFOLD < REMOVAL AND INSTALLATION > [VQ40DE] INTAKE MANIFOLD A Exploded View INFOID:0000000010709714 EM C D E F G PBIC2878E 1. 3. Refer to EM-162. REMOVAL J 1. 2.. etc. Gasket H Removal and Installation INFOID:0000000010709715 NOTE: I When removing components such as hoses. Remove gaskets. CAUTION: O Cover engine openings to avoid entry of foreign materials. Refer to EM-142. "Removal and Installation". cap or plug openings to prevent fluid from spill- ing.

replace intake manifold. Revision: August 2014 EM-146 2015 Frontier NAM .0 kg-m. • Perform the "Idle Air Volume Learning" and "Throttle Valve Closed Position Learning" when electric throttle control actuator is replaced.4 N·m (0. • Erase CPU memory. PBIC0870E INSTALLATION Installation is in the reverse order of removal. Intake manifold bolt and nuts 1st step : 7. 8 ft-lb) • Tighten all nuts and bolts to the specified torque in two or more steps in numerical order as shown. "Throttle Valve Closed Position Learning". "Idle Air Volume Learning". Limit : 0. 21 ft-lb) PBIC2879E • Adjust neutral position steering angle sensor. • Perform the "Throttle Valve Closed Position Learning" when harness connector of electric throttle control actuator is disconnected. install them and tighten to the specified torque. 65 in-lb) 2nd step and after : 29.004 in) • If it exceeds the limit.75 kg-m. Intake manifold studs : 10. INTAKE MANIFOLD < REMOVAL AND INSTALLATION > [VQ40DE] • Check the surface distortion of the intake manifold mating surface with straightedge and feeler gauge.8 N·m (1. Refer to EC-593. Note the following: Intake Manifold • If stud bolts were removed from cylinder head. Refer to EC-593.1kg-m.1 mm (0.0 N·m (3.

Exhaust manifold nuts (RH) 6. "Exploded View". Exhaust manifold studs (LH) M Removal and Installation (Three Way Catalyst) INFOID:0000000010709717 N WARNING: Perform the work when the exhaust and cooling system have cooled sufficiently. Exhaust manifold nuts (LH) 19. Seal ring 11. 6. Revision: August 2014 EM-147 2015 Frontier NAM . Exhaust manifold (LH) 18. Seal ring 14. REMOVAL O 1. Refer to EXT-27. Remove the center exhaust tube. Refer to WT-48. Gasket 5. Three way catalyst nuts (RH) 12. "Adjustment". Three way catalyst studs (RH) 10. 4. Three way catalyst studs (LH) 15. Exhaust manifold (RH) 7. Remove the exhaust manifold cover bolts. 7. Exhaust manifold studs (RH) K 4. Disconnect harness connector from the air fuel ratio sensor 1. Exhaust manifold cover (LH) 17. 5. Exhaust manifold cover (RH) 8. Remove the three way catalyst nuts and remove the three way catalyst. Remove the front wheel and tire. Three way catalyst (LH) 16. Remove the mud guard and front fender protector. 2. P 3. "Removal and Installation of Front Fender Protector". Gasket 20. Three way catalyst (RH) 9. Cylinder head (LH) 2. if necessary. Three way catalyst nuts (LH) L 13. EXHAUST MANIFOLD AND THREE WAY CATALYST < REMOVAL AND INSTALLATION > [VQ40DE] EXHAUST MANIFOLD AND THREE WAY CATALYST A Exploded View INFOID:0000000010709716 EM C D E F G H I J ALBIA0654GB 1. Remove the air fuel ratio sensor 1 using Tool. Refer to EX-5. Cylinder head (RH) 3. main muffler and front exhaust tube.

"Exploded View". Remove heater pipe from cylinder head (LH). 7 and 8 in removal. Remove gaskets. "Changing Engine Coolant". Refer to CO-40. 7. clean exhaust system threads using oxygen sensor thread cleaner and apply anti-seize lubricant.1 kg-m. Refer to CO-57. 2. 9. Remove engine under cover (if equipped). Remove air cleaner case (upper) and air duct and resonator assembly. 3. Remove engine room cover using power tool.5 m (19. INSPECTION AFTER REMOVAL Revision: August 2014 EM-148 2015 Frontier NAM . INSTALLATION Installation is in the reverse order of removal. replace with a new sensor. Refer to EXT-15. 11. 5. 6. NOTE: When removing components such as hoses. Partially drain engine coolant. • Tighten air fuel ratio sensor 1 to specification. Remove exhaust manifold (LH). "Exploded View". Refer to EM-140. Refer to CO-57. 37 ft-lb) CAUTION: • Do not over tighten air fuel ratio sensor 1. "Removal and Installation". • Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0. "Removal and Installation (Three Way Catalyst)". Loosen nuts in reverse order as shown. Remove three way catalyst (LH). "Removal and Installation". Refer to EM-141. tubes/lines. • Before installing a new air fuel ratio sensor 1. CAUTION: Cover engine openings to avoid entry of foreign materials. Refer to EM-147. resulting in the “MIL” coming on. cap or plug openings to prevent fluid from spill- ing. Doing so may cause damage to air fuel ratio sensor 1. if removed.0 N·m (5. AWBIA0725ZZ 10. "Removal and Installation". Refer to EM-151. • : Front NOTE: Disregard the numerical order No.. 8. Disconnect water hoses at heater pipe. 4. "Exploded View".7 in) onto a hard surface such as a concrete floor. etc. Remove oil level gauge and oil level gauge guide. Air fuel ratio sensor : 50. 1. EXHAUST MANIFOLD AND THREE WAY CATALYST < REMOVAL AND INSTALLATION > [VQ40DE] Tool number : KV991J0050 (J-44626) CAUTION: • Be careful not to damage air fuel ratio sensor 1. Oxygen sensor thread cleaner : — (J-43897-12) Oxygen sensor thread cleaner : — (J-43897-18) Removal and Installation (Exhaust Manifold) INFOID:0000000010709718 REMOVAL (LH) WARNING: Perform the work when the exhaust and cooling system have cooled sufficiently.

"Removal and Installation (Three Way Catalyst)". Revision: August 2014 EM-149 2015 Frontier NAM . 4. 7 K and 8 show second step. NOTE: Tighten nuts No. 7 and 8 in removal. Loosen nuts in reverse order as shown. Refer to EM-147. install them and tighten to specification. J CAUTION: Use new exhaust manifold nuts for installation. A face with straightedge and feeler gauge. Remove support bolts from A/T fluid charging pipe (A/T models). Limit : 0. Refer to TM-304. • : Front O NOTE: Disregard the numerical order No. replace exhaust manifold. C PBIC1096E D INSTALLATION (LH) Installation is in the reverse order of removal. 1 and 2 in two steps. • : Front F • A: Identification hole G H AWBIA0726ZZ Exhaust Manifold I • If exhaust manifold studs were removed. • Install exhaust manifold and tighten nuts in numerical order as shown. N 3. Remove three way catalyst (RH). P AWBIA0727ZZ 5. Remove exhaust manifold (RH) and exhaust manifold cover (RH) together. "Component". E Exhaust Manifold Gasket Install the exhaust manifold gasket in direction as shown. EXHAUST MANIFOLD AND THREE WAY CATALYST < REMOVAL AND INSTALLATION > [VQ40DE] Surface Distortion • Check the surface distortion of the exhaust manifold mating sur. 2. The numerical order No. . : Front L AWBIA0725ZZ REMOVAL (RH) M 1.3 mm (0.012 in) EM • If it exceeds the limit. Remove heat shield from lower dash panel.

Remove gaskets. Exhaust Manifold Gasket Install the exhaust manifold gaskets in direction as shown. PBIC1096E INSTALLATION (RH) Installation is in the reverse order of removal. • : Front • A: Identification hole AWBIA0728ZZ Exhaust Manifold • If exhaust manifold studs were removed. • Install exhaust manifold and tighten nuts in numerical order as shown. CAUTION: Cover engine openings to avoid entry of foreign materials. : Front AWBIA0727ZZ Revision: August 2014 EM-150 2015 Frontier NAM . a crowfoot may be used to tighten the exhaust manifold nuts.012 in) • If it exceeds the limit. The numerical order No. NOTE: Tighten nuts No. 1 and 2 in two steps. install them and tighten to specification.3 mm (0. Limit : 0. replace exhaust manifold. CAUTION: Use new exhaust manifold nuts for installation. EXHAUST MANIFOLD AND THREE WAY CATALYST < REMOVAL AND INSTALLATION > [VQ40DE] 6. NOTE: If necessary. . INSPECTION AFTER REMOVAL Surface Distortion • Check the surface distortion of the exhaust manifold mating sur- face with straightedge and feeler gauge. 7 and 8 show second step.

Drain engine oil. "Removal and Installation". cap or plug openings to prevent fluid from spill- ing. 3. O-ring 6. Oil cooler 7. Oil pan (upper) 2. Drain plug washer 11. P 2. Oil pan (lower) 12. Drain plug 10. Remove oil pan (lower) using the following steps. Connector bolt 8. Relief valve 5. do not drain engine oil when engine is hot. "Changing Engine Oil". etc. NOTE: O When removing components such as hoses. Revision: August 2014 EM-151 2015 Frontier NAM . O-ring K 4.. 1. Refer to EXT-15. Remove the engine under cover (if equipped). Oil level gauge guide 16. OIL PAN AND OIL STRAINER < REMOVAL AND INSTALLATION > [VQ40DE] OIL PAN AND OIL STRAINER A Exploded View INFOID:0000000010709719 EM C D E F G H I J PBIC2883E 1. Refer to LU-23. Oil strainer 14 O-ring 15. Oil filter 9. Rear cover plate L 13. Oil level gauge M Removal and Installation INFOID:0000000010709720 REMOVAL (LOWER) N WARNING: To avoid the danger of being scalded. Oil pressure switch 3. tubes/lines.

PBIC2889E c. Use scraper to remove old liquid gasket from mating surfaces. Use Genuine RTV Silicone Sealant or equivalent. Remove the oil pan (lower) bolts using power tool in reverse order as shown. this will damage the mating surfaces. Install oil pan (lower) as follows: a. WBIA0566E INSPECTION AFTER REMOVAL Clean oil strainer if any object attached. Apply a continuous bead of liquid gasket using a suitable tool to the oil pan (lower) as shown. OIL PAN AND OIL STRAINER < REMOVAL AND INSTALLATION > [VQ40DE] a. Refer to GI-21. CAUTION: Do not scratch or damage the mating surfaces when clean- ing off old liquid gasket. PBIC2890E b. INSTALLATION (LOWER) 1. PBIC2888E b. "Recommended Chemical Products and Sealants". Install oil pan (lower). • Do not insert screwdriver. Insert Tool between the oil pan (lower) and the oil pan (upper). CAUTION: Attaching should be done within 5 minutes after coating. • Remove old liquid gasket from the bolt holes and thread. • Also remove old liquid gasket from mating surface of oil pan (upper). NOTE: Tap (1) Tool to insert it and then slide (2) it by tapping on the side of the Tool as shown. Revision: August 2014 EM-152 2015 Frontier NAM . Tool number : KV10111100 (J-37228) CAUTION: • Be careful not to damage the mating surfaces.

Disconnect steering gear lower joint shaft bolt and steering gear nuts and bolts. 4. Remove stabilizer bar brackets and position stabilizer bar out of the way. NOTE: When removing components such as hoses. Refer to LU-23. Refer to TM-304. After 30 minutes fill with engine oil and inspect for leaks. Remove transmission joint bolts which pierce oil pan (upper). L 5. 6. CAUTION: E Do not fill the engine with oil for at least 30 minutes after oil pan is installed. "Removal and Installation". Remove oil level gauge and oil level gauge guide. G 3. 12. "Removal and Installation". P 14. do not drain engine oil when engine is hot. Refer to DLN-191. "Removal and Installation". Refer to EXT-15. 2. Install engine under cover (if equipped). "Removal and Installation". • Do not spill engine oil on drive belts. Refer to EM-151. "Removal and Installation". J • Do not spill engine coolant on drive belts. K 3. 10. Refer to TM-72. Stop engine and wait for 10 minutes. Refer to ST-15. Remove oil pressure switch if necessary. cap or plug openings to prevent fluid from spill. Refer to EM-151. "Component". Remove oil cooler. 16. 8.. Remove oil strainer. 2. M 7. tubes/lines. "Removal and Installation from Vehicle (For 2WD Models)" (2WD M/T models). Start engine. Install oil pan drain plug. Disconnect oil cooler hoses. "Removal and Installation from Vehicle (For Revision: August 2014 EM-153 2015 Frontier NAM . etc. Refer to BR-36. 3. Disconnect A/T fluid cooler tube brackets and position out of the way (A/T models). Remove oil pan (lower). position out of the way. "Removal and Installation of Brake Caliper and Disc Rotor". Refer to FSU-13. TM-74. REMOVAL (UPPER) WARNING: H To avoid the danger of being scalded. O 11. Refer to CO-40. Check engine oil level. "Changing Engine Oil". "Removal and Installation". Remove engine under covers (if equipped). "Inspection". if necessary. Reposition the (RH) brake caliper aside and support with a suitable wire without disconnecting the front brake hose (4WD models). N 9. Remove front frame crossmember. Drain engine coolant. 13. Refer to LU-22. OIL PAN AND OIL STRAINER < REMOVAL AND INSTALLATION > [VQ40DE] • Tighten oil pan (lower) bolts in numerical order as shown. I ing. INSPECTION AFTER INSTALLATION F 1. 1. Remove oil filter. if necessary. "Changing Engine Coolant". "Removal and Installation". 15. Remove front final drive (4WD models). Refer to LU-25. Refer to LU-27. and check for leaks of engine oil. 4. Disconnect oil pressure switch. "Component". 17. A EM C PBIC2890E D 2. CAUTION: • Perform this procedure when engine is cold.

CAUTION: • Do not reuse the three O-rings. WBIA0566E 20. "Removal and Installation for VQ40DE 4WD Models" (4WD A/T models). TM-308. PBIC2887E • Insert Tool between oil pan (upper) and lower cylinder block. • Install a new O-ring in the upper oil pan and two new O- rings in the front cover. PBIC2884E Revision: August 2014 EM-154 2015 Frontier NAM . Install oil pan (upper) as follows: a. • Remove old liquid gasket from the bolt holes and threads. PBIC2885E INSPECTION AFTER REMOVAL Clean oil strainer. OIL PAN AND OIL STRAINER < REMOVAL AND INSTALLATION > [VQ40DE] 4WD Models)" (4WD M/T models). Tool number : KV10111100 (J-37228) CAUTION: Be careful not to damage mating surfaces. CAUTION: Do not scratch or damage the mating surfaces when clean- ing off old liquid gasket. Tap (1) Tool to insert it and then slide (2) it by tapping on the side as shown. TM-310. Use scraper to remove old liquid gasket from mating surfaces. "Removal and Installation for VQ40DE 2WD Models" (2WD A/T models). 19. Remove rear cover plate. 18. Remove oil pan (upper) bolts with power tool in reverse order as shown. INSTALLATION (UPPER) 1. • Also remove the old liquid gasket from mating surface of lower cylinder block. Remove O-rings from bottom of lower cylinder block and oil pump.

Install new O-rings on the bottom of lower cylinder block and oil pump. Install oil pan (upper). • Install a new O-ring in the upper oil pan and two new O- EM rings in the front cover. "Removal and Installation for VQ40DE 2WD Models" (2WD A/T models). J M8 × 100 mm (3. I • Tighten oil pan (upper) bolts in numerical order as shown. Installation of the remaining components is in the reverse order of removal. 13 M8 × 25 mm (0. NOTE: Revision: August 2014 EM-155 2015 Frontier NAM . N 3. • Apply a bead of 4. check for fuel leak- age at connection points. "Removal and Installation for VQ40DE 4WD Models" (4WD A/T models).217 in) in diame- ter to area (A). check oil/fluid levels including engine coolant and engine oil. apply liquid gasket outside F the hole. CAUTION: • For bolt holes with mark. H CAUTION: • Install avoiding misalignment of both oil pan gaskets and O-rings. TM-308. • Start engine. Refer to MA-19. Install oil strainer to oil pan (upper). • Use procedure below to check for fuel leakage. • Install a new O-ring in the upper oil pan and two new O-rings in the front cover. "Removal and Installation from Vehicle (For 2WD Mod- els)" (2WD M/T models). "FOR MEXICO : Fluids and Lubricants" (Mexico). • Run engine to check for unusual noise and vibration. E Use Genuine RTV Silicone Sealant or equivalent. OIL PAN AND OIL STRAINER < REMOVAL AND INSTALLATION > [VQ40DE] b. O INSPECTION AFTER INSTALLATION • Before starting engine.177 to 0. If less than required quantity. TM-74. 11. 2. Apply a continuous bead of liquid gasket using a suitable tool to the lower cylinder block mating surfaces of oil pan (upper) as shown. • Do not reuse the three O-rings. Refer to TM-72. A CAUTION: • Do not reuse the three O-rings. check again for fuel leakage at connection points.98 in) : All except the above K L PBIC2887E e.5 mm (0.5 to 5. • There are two types of bolts. G • Attaching should be done within 5 minutes after coating. With fuel pressure applied to fuel piping. fill to the specified level. • Turn ignition switch ON (with engine stopped). TM-310. PBIC2886E d. With engine speed increased. 12.97 in) : 7. "Recommended Chemical Products and Sealants". C PBIC2885E D c. Refer to MA-16. CAUTION: Do not fill the engine with oil for at least 30 minutes after oil pan is installed. "Removal and Installation from Vehicle (For 4WD Models)" (4WD M/T M models). "FOR USA AND CANADA : Fluids and Lubricants" (United P States and Canada). Refer to GI-21. Tighten transmission joint bolts.

exhaust gas. Noise will stop after hydraulic pressure rises. if necessary. Refill to spec- ified level. etc. such as in cooling system. Revision: August 2014 EM-156 2015 Frontier NAM . brake fluid. However. slack in the guide may generate a pounding noise during and just after engine start. OIL PAN AND OIL STRAINER < REMOVAL AND INSTALLATION > [VQ40DE] If hydraulic pressure inside timing chain tensioner drops after removal and installation. • Summary of the inspection items: Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage Other oils and fluids* Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas — Leakage — *Power steering fluid. or any oils/fluids including engine oil and engine coolant. • After cooling down engine. again check oil/fluid levels including engine oil and engine coolant. • Warm up engine thoroughly to make sure there is no leakage of fuel. • Bleed air from passages in lines and hoses. this is normal.

"Removal and Installation". CAUTION: Do not shock ignition coil. REMOVAL (RH) L 1. harness bracket. Refer to EM-142. 3. N INSTALLATION (RH) Installation is in the reverse order of removal. Disconnect the harness connector from ignition coil. 3. harness bracket. K INSTALLATION (LH) Installation is in the reverse order of removal. Ignition coil 2. Remove the ignition coil. IGNITION COIL < REMOVAL AND INSTALLATION > [VQ40DE] IGNITION COIL A Exploded View INFOID:0000000010709721 EM C D E F G PBIC2901E 1. Remove intake manifold collector. Disconnect the harness connector from ignition coil. J CAUTION: Do not shock ignition coil. M 4. and hoses located above ignition coil. 2. Move aside harness. Move aside harness. Spark plug H Removal and Installation INFOID:0000000010709722 REMOVAL (LH) I 1. Remove the ignition coil. 2. O P Revision: August 2014 EM-157 2015 Frontier NAM . and hoses located above ignition coil.

"Exploded View". Separate engine harness removing their brackets from rocker covers. 4. PCV hose Removal and Installation INFOID:0000000010709724 REMOVAL (LH) 1. if necessary. PCV valve 4. Rocker cover (LH) 10. Remove harness bracket from cylinder head. • : Front AWBIA0729ZZ Revision: August 2014 EM-158 2015 Frontier NAM . Rocker cover gasket (RH) 8. Remove ignition coils. Rocker cover (RH) 6. Refer to EM-157. Disconnect the intake valve timing control solenoid valve (LH bank). Remove the rocker cover bolts using power tool in reverse order as shown. Rocker cover gasket (LH) 9. 3. 2. Refer to EM-168. 5. 7. Oil filler cap 2. Remove PCV hoses from rocker covers. 6. "Removal and Installation". Remove oil filler cap from rocker cover (LH). ROCKER COVER < REMOVAL AND INSTALLATION > [VQ40DE] ROCKER COVER Exploded View INFOID:0000000010709723 PBIC2905E 1. PCV hose 7. PCV hose 3. if necessary. O-ring 5.

18 in) from connector end. Refer to EM-142. P REMOVAL (RH) 1. • Insert PCV hose by 25 to 30 mm (0. A 10.33 N·m (0. 1) as follows: Use Genuine RTV Silicone Sealant or equivalent. Remove intake manifold collector. be careful not to twist or come in contact with other parts. EM INSTALLATION (LH) 1. Tighten the rocker cover bolts in two steps in numerical order as K shown. Install rocker cover. Install new rocker cover gasket to rocker cover. NOTE: D The figure shows an example of LH side [zoomed in shows camshaft bracket (No. Install PCV hose. Remove rocker cover. • Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover. 9. if removed. Revision: August 2014 EM-159 2015 Frontier NAM . 4. b. "Removal and Installation". 2. Apply liquid gasket using a suitable tool to joint of rocker cover. Separate engine harness removing their brackets from rocker covers. J 3. 1)].96 N·m (0. a. 7. Apply liquid gasket to joint part of camshaft bracket (a) (No. 1). CAUTION: Perform this step when engine is cold. 1) E and cylinder head. "Inspection". F G H I PBIC2474E 2. Apply liquid gasket (b) 90° to figure (a). O • When installing. Refer to GI-21. CAUTION: Do not scratch or damage the mating surface when cleaning off old liquid gasket. 6. "Recommended Chemical Products and Sealants". Installation of the remaining components is in the reverse order of removal. 74 in-lb) M AWBIA0729ZZ N 5.98 to 1.85 kg-m. Refer to LU-22. C cylinder head and camshaft bracket (No. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. Remove rocker cover gaskets from rocker covers.20 kg-m. ROCKER COVER < REMOVAL AND INSTALLATION > [VQ40DE] 8. Install oil filler cap to rocker cover (LH). 17 in-lb) 2nd step : 8. • Check engine oil level and adjust as necessary. • : Front L 1st step : 1.

11. 8. Remove the rocker cover bolts using power tool in reverse order as shown. Refer to EM-157. Apply liquid gasket (b) to the figure (a) squarely. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 7. cylinder head and camshaft bracket (No. 1)]. 5. Remove harness bracket from cylinder head (RH). "Recommended Chemical Products and Sealants". Refer to GI-21. Refer to EM-168. • Check to be sure rocker cover gasket is not dropped from installation groove of rocker cover. 1). 1) and cylinder head. Remove rocker cover gaskets from rocker covers. Revision: August 2014 EM-160 2015 Frontier NAM . Disconnect the intake valve timing control solenoid valve (RH bank). 6. Remove the PCV hoses from rocker cover. b. Remove the PCV valve and O-ring from rocker cover (RH). "Removal and Installation". CAUTION: Do not scratch or damage the mating surface when cleaning off old liquid gasket. 3. INSTALLATION (RH) 1. CAUTION: Do not reuse O-rings. • : Front AWBIA0730ZZ 9. 1) as fol- lows: Use Genuine RTV Silicone Sealant or equivalent. a. "Removal and Installation". if necessary. Apply liquid gasket to joint part of camshaft bracket (a) (No. 10. 4. Remove rocker cover. Apply liquid gasket using a suitable tool to joint part among rocker cover. "Exploded View". Install new rocker cover gasket to rocker cover. ROCKER COVER < REMOVAL AND INSTALLATION > [VQ40DE] 3. Install rocker cover. Remove the ignition coils. PBIC2474E 2. Refer to EM-205. NOTE: The figure shows an example of LH side [zoomed in shows camshaft bracket (No.

Installation of the remaining components is in the reverse order of removal. • Insert PCV hose by 25 to 30 mm (0. Tighten the rocker cover bolts in two steps in numerical order as shown. E 6. Install PCV hose.85 kg-m. be careful not to twist or come in contact with other parts.33 N·m (0. if removed. G H I J K L M N O P Revision: August 2014 EM-161 2015 Frontier NAM . CAUTION: Do not reuse O-rings. 7.96 N·m (0.20 kg-m.18 in) from connector end. ROCKER COVER < REMOVAL AND INSTALLATION > [VQ40DE] 4. A • : Front 1st step : 1. Install new O-ring and PCV valve to rocker cover (RH). 17 in-lb) EM 2nd step : 8. • When installing.98 to 1. "Inspection". 74 in-lb) C AWBIA0730ZZ D 5. Refer to LU-22. F • Check engine oil level and adjust as necessary.

• Do not smoke while servicing fuel system. Fuel damper 11. cap or plug openings to prevent fluid from spill- ing. O-ring 9. O-ring (blue) 6. tubes/lines. Refer to PG-89.. O-ring 3. Fuel feed hose Removal and Installation INFOID:0000000010709726 WARNING: • Put a “CAUTION FLAMMABLE” sign in the workshop. "Fuel Pressure Check". FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION > [VQ40DE] FUEL INJECTOR AND FUEL TUBE Exploded View INFOID:0000000010709725 PBIC2957E 1. NOTE: When removing components such as hoses. do not drain engine coolant when engine is hot. Spacer 10. etc. Disconnect the battery negative terminal. Fuel tube (RH) 2. O-ring (brown) 8. Fuel injector 7. 3. Refer to EC-968. "Removal and Installation". Remove the intake manifold collector. Fuel damper cap 12. Fuel tube (LH) 4. REMOVAL 1. • Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. CAUTION: Revision: August 2014 EM-162 2015 Frontier NAM . 2. CAUTION: Do not remove or disassemble parts unless instructed. "Removal and Installation". Refer to EM-142. Keep open flames and sparks away from the work area. Quick connector cap 13. • To avoid the danger of being scalded. Release the fuel pressure. Clip 5.

EM C LBIA0090E D b. E Tool number : — (J-45488) c. Insert Tool into quick connector until sleeve contacts and goes F no further. O CAUTION: Do not tilt it. • Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of for- eign materials. 4. • Do not reuse O-rings. I • Avoid fire and sparks. • Do not expose parts to battery electrolyte or other acids. N 6. O-ring inside quick connector may be damaged. With the sleeve side of Tool facing quick connector. Pull the quick connector straight out from the fuel tube. Remove quick connector cap. CAUTION: Inserting the Tool hard will not disconnect quick connector. as shown. • Do not pull with lateral force applied. • Do not bend or twist connection between quick connector and fuel feed hose during removal J and installation. d. and remove fuel tube and fuel injector assembly. G Hold Tool where it contacts and goes no further. Hold the Tool on that position. Remove PCV hose between rocker covers (right and left banks). or remaining fuel in pipes may flow out from pipes. A a. install Tool onto fuel tube. 7. • Prepare container and cloth beforehand as fuel will leak out. Disconnect harness connector from fuel injector. WBIA0295E CAUTION: H • Pull quick connector holding it at the (A) position. Loosen bolts in reverse order as shown. K L M PBIC1899E 5. Disconnect the fuel quick connector on the engine side. FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION > [VQ40DE] Perform this step when engine is cold. P PBIC2902E Revision: August 2014 EM-163 2015 Frontier NAM .

If O-ring was stretched while it was being attached. do not scratch it with tool or fin- gernails. CAUTION: • Insert straight. CAUTION: • Be careful with remaining fuel that may leak out from fuel tube. • Do not reuse O-rings. INSTALLATION 1. make sure that there is no gap between fuel damper cap and fuel tube. • Lubricate new O-ring with new engine oil. • Do not reuse O-rings. Tighten bolts evenly in turn. if necessary. • Insert new O-ring straight into fuel tube. Disconnect fuel tube (RH) from fuel tube (LH). d. • Do not pressure-fit with excessive force. Install new O-ring to fuel tube as shown. • After tightening bolts. Remove fuel injector from fuel tube as follows: a. b.3 kg. Install fuel damper as follows: a. • Do not disassemble fuel injectors. Revision: August 2014 EM-164 2015 Frontier NAM . Remove fuel injector from fuel tube by pulling straight. • When handling new O-rings. • Do not damage injector nozzles during removal. Install new O-rings to fuel injector. • Do not clean O-ring with solvent. FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION > [VQ40DE] 8. Install spacer to fuel damper. paying attention to the following. be careful of the following cau- tion: CAUTION: • Handle O-ring with bare hands. Loosen bolts. Do not wear gloves. allow it to retract before inserting it into fuel tube. to remove fuel damper cap and fuel damper. • Do not twist or stretch O-ring. Do not angle or twist it. Insert fuel damper straight into fuel tube. 2. b. Remove bolts which connects fuel tube (RH) and fuel tube (LH).2 lb) • Insert fuel damper until (B) is touching (A) of fuel tube. PBIC2903E Reference value : 130 N (13. • When installing O-ring. 11. PBIC2999E 10. 9. c. making sure that the axis is lined up. Carefully open and remove clip. • Make sure that O-ring and its mating part are free of for- eign material. 29. • Do not bump or drop fuel injectors.

allow it to retract before inserting it into fuel tube. • Lubricate O-ring with new engine oil. CAUTION: • Handle O-ring with bare hands. allow it to retract before inserting it into fuel tube. Replace it with a new one. Connect the fuel tube (RH) to the fuel tube (LH). M • Do not reuse O-rings. If O-ring was stretched while it was being attached. • When installing O-ring. If interference occurs. c. FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION > [VQ40DE] CAUTION: • Do not reuse O-rings. • Insert O-ring straight into fuel injector. • Lubricate O-ring with new engine oil. O • Insert new O-ring straight into fuel tube. replace O-ring. • Do not twist or stretch O-ring. I • Make sure that fuel tube flange (F) is secured in flange attach- ing groove (D) on clip (3). If O-ring was stretched while it was being attached. • Do not allow the clip (3) to interfere with the O-ring (2). Make sure that installation is complete by checking that fuel J injector does not rotate or come off. Do not angle or twist it. • Insert it while matching it to the axial center. • Do not clean O-ring with solvent. 5. be careful not to scratch it with tool or fingernails. E a. Do not wear gloves. A • Upper and lower O-ring are different colors. 3. Do not wear gloves. H b. • Tighten bolts to the specified torque after installing fuel tube and fuel injector assembly. Install fuel tube and fuel injector assembly to intake manifold. CAUTION: P Do not let the tip of the injector nozzle come in contact with other parts. Insert fuel injector (5) into fuel tube (1) with clip (3) attached. • Make sure that O-ring and its mating part are free of foreign material. Install fuel injector (5) to fuel tube (1). K AWBIA1159GB L 4. CAUTION: • Do not reuse O-ring (2 and 4). • Insert clip (3) so that protrusion of fuel injector matches cutout F (C) of clip. be careful not to scratch it with tool or fingernails. Do not angle or twist it. • Insert fuel injector so that protrusion of fuel tube (A) matches cutout of clip (3). G • Do not reuse clip. and tighten bolts temporarily. • When installing O-ring. Revision: August 2014 EM-165 2015 Frontier NAM . • Make sure that protrusions of fuel injectors (5) are aligned with cutouts of clips (B) after installation. Fuel tube side : Blue EM Nozzle side : Brown • Handle O-ring with bare hands. N • Make sure that O-ring and its mating part are free of foreign material. C • Do not clean O-ring with solvent. Insert new clip (3) into clip mounting groove (E) on fuel injector (5). D • Do not twist or stretch O-ring.

16 ft-lb) PBIC2902E 6.0 kg-m. Installation of the remaining components is in the reverse order of removal. 7 ft-lb) 2nd step : 22. Revision: August 2014 EM-166 2015 Frontier NAM . Install intake manifold collector. NOTE: Use mirrors for checking at points out of clear sight.1 N·m (1. Then check for fuel leaks at the connections. FUEL INJECTOR AND FUEL TUBE < REMOVAL AND INSTALLATION > [VQ40DE] • Tighten bolts in two steps in numerical order as shown. Start the engine and rev it up and check for fuel leaks at the connections. 2. Refer to EM-142.2 kg-m. 8. Apply fuel pressure to the fuel lines by turning ignition switch ON (with engine stopped).0 N·m (2. INSPECTION AFTER INSTALLATION Check on Fuel Leakage 1. Tighten bolts which connect fuel tube (RH) and fuel tube (LH) to the specified torque. as engine becomes extremely hot. "Removal and Installation". 7. Connect fuel injector harness connector. 9. Fuel injector tube assembly bolts 1st step : 10. WARNING: Do not touch engine immediately after stopping.

Remove intake manifold collector. Remove intake valve timing control solenoid valve bolts (RH) and O-ring from rocker cover. Disconnect harness connector from intake valve timing control solenoid valve (RH). Refer to EM-192. Refer to EM-142. Refer to EM-192. INSTALLATION Installation is in the reverse order of removal. INTAKE VALVE TIMING CONTROL < REMOVAL AND INSTALLATION > [VQ40DE] INTAKE VALVE TIMING CONTROL A Intake Valve Timing Control Solenoid Valve (LH) INFOID:0000000010709727 REMOVAL EM 1. • Lubricate the new O-ring for the intake valve timing control solenoid valve with clean engine oil before installing. "Removal and Installation". Intake Valve Timing Control Solenoid Valve (RH) INFOID:0000000010709728 F REMOVAL 1. I CAUTION: • Do not reuse O-rings. "Exploded View". CAUTION: H Do not reuse O-ring. "Exploded View". J K L M N O P Revision: August 2014 EM-167 2015 Frontier NAM . CAUTION: C Do not reuse O-ring. 2. Remove intake valve timing control solenoid valve bolts (LH) and O-ring from rocker cover. • Lubricate the new O-ring for the intake valve timing control solenoid valve with clean engine oil E before installing. 3. G 2. INSTALLATION Installation is in the reverse order of removal. D CAUTION: • Do not reuse O-rings. Disconnect harness connector from intake valve timing control solenoid valve (LH).

"Removal and Installation (Motor driven type)". Collared O-ring 8. O-ring A. Front oil seal 13. "Removal and Installation". "Changing Engine Oil". Cooling fan bracket 11. CAUTION: • Perform this step when engine is cold. Refer to EM-129. 8. Refer to CO-40. Refer to LU-23. if necessary. Front timing chain case 15. and temporarily secure it aside. Crankshaft pulley 12. 2. • Do not spill engine coolant on drive belts. Drive belt auto-tensioner 6. Intake valve timing control cover (RH) 4. Refer to EM-168 Removal and Installation INFOID:0000000010709730 REMOVAL 1. Chain tensioner cover 10. "Changing Engine Coolant". Idler pulley 5. Remove engine cooling fan (Motor driven type). Remove EVAP canister purge volume control solenoid valve. Intake valve timing control cover (LH) 7. O-ring 9. 6. 5. Refer to EM-140. Drain engine oil. Disconnect engine harnesses and remove harness brackets from front timing chain case. "Removal and Installation". Remove drive belt. Water pump cover 14. Revision: August 2014 EM-168 2015 Frontier NAM . Refer to ST-19. Collared O-ring 3. Refer to CO-48. CAUTION: • Perform this step when engine is cold. Remove engine room cover using power tool. FRONT TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] FRONT TIMING CHAIN CASE Exploded View INFOID:0000000010709729 AWBIA1522ZZ 1. O-ring 2. Drain engine coolant from radiator. • Do not spill engine oil on drive belts. 3. 7. Remove power steering oil pump from bracket with piping connected. 4. "Removal and Installation".

Refer to CO-47. keep it horizontal until it is completely disconnected. F SEM728G 16. Remove generator. D Tool number : KV10111100 (J-37228) CAUTION: • Shaft is internally jointed with camshaft sprocket (INT) E center hole. Refer to EM-168. K 18. EM 13. Remove access plate and install Ring Gear Stopper Tool. "Removal and Installation for Compressor". 10. Remove power steering oil pump bracket. Keep loosened crankshaft pulley bolt in place to protect the crankshaft pul. FRONT TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] 9. L Tool number : KV11105210 (J-44716) b. When removing. Refer to HA-25. Remove right and left intake valve timing control covers. Loosen crankshaft pulley bolt so that there is a 10 mm (0. Refer to CHG-29. • Do not damage the mating surfaces.VQ40DE Models". Remove A/C compressor bolts and temporarily secure A/C compressor aside. CAUTION: Do not reuse O-rings. 12. Remove water bypass hoses and water hose clamp. Remove crankshaft pulley as follows: a. A 11. Revision: August 2014 EM-169 2015 Frontier NAM . Remove engine cooling fan (Crankshaft driven type) and fan bracket. Remove collared O-rings from front timing chain case (left and G right side). N ley from dropping. "Exploded View". "Removal and Installation (Crankshaft driven type)". 14. Refer to ST-19. • Loosen bolts in reverse order as shown. Pull crankshaft pulley with both hands to remove it. Remove water hose at oil cooler. • Cut liquid gasket for removal using Tool. Remove oil cooler water bypass pipe from front timing chain case. "Removal and Installation". O PBIC2918E P c. H I PBIC2631E J 17. "Removal and Installation . C 15. M CAUTION: Do not remove crankshaft pulley bolt.39 in) gap between bolt and crankshaft pulley.

PBIC2907E 20. Remove front timing chain case as follows: a. CAUTION: Do not reuse O-rings. or warp under a load. • After removal. c. remove water pump cover and chain tensioner cover from front timing chain case. Loosen two bolts in front of oil pan (upper) in reverse order as shown. If necessary. • Do not damage the mating surfaces. • Cut liquid gasket for removal using Tool. Revision: August 2014 EM-170 2015 Frontier NAM . bend. • Cut liquid gasket for removal using Tool. Tool number : KV10111100 (J-37228) CAUTION: • Do not use screwdriver or something similar. Loosen bolts with power tool in reverse order as shown. PBIC2548E 22. Insert suitable tool into the notch at the top of the front timing chain case as shown (1). handle front timing chain case carefully so it does not twist. Pry off case by moving tool as shown (2). SEM156F 21. FRONT TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] 19. Tool number : KV10111100 (J-37228) CAUTION: Do not damage the mating surfaces. Remove O-rings from rear timing chain case. PBIC2908E b.

M N SEM926E O INSTALLATION P Revision: August 2014 EM-171 2015 Frontier NAM . CAUTION: Be careful not to allow gasket fragments to enter oil pan. 25. if necessary. I J K PBIC2084E 26. chain tensioner cover (if necessary) and intake valve timing control covers. oil pan (upper). Use a scraper to remove all traces of old liquid gasket from L water pump cover. EM C PBIC2909E D 24. Refer to EM-130. and liquid gasket E mating surfaces. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases. "Drive Belt Auto-Tensioner and Idler Pulley". F G PBIC2910E H • Remove old liquid gasket from bolt hole and thread. Remove front oil seal from front timing chain case using suitable tool. FRONT TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] 23. Remove idler pulley. A CAUTION: Be careful not to damage front timing chain case.

FRONT TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] 1. Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length. 5. CAUTION: • Be careful not to damage front timing chain case and crankshaft. • Make sure the garter spring is in position and seal lip is not inverted. Use Genuine RTV Silicone Sealant or equivalent. • Apply a continuous bead of liquid gasket using a suitable tool to front timing chain case as shown. if removed.36 in)]. Refer to GI-21. Install front timing chain case as follows: Revision: August 2014 EM-172 2015 Frontier NAM . PBIC2911E 3. if removed. PBIC2912E 4. • Press-fit straight and avoid causing burrs or tilting oil seal. NOTE: Be sure to place dowel pins in the original holes in front timing chain case. Install water pump cover and chain tensioner cover to front timing chain case. Install new front oil seal on the front timing chain case. SEM715A • Press-fit oil seal until it becomes flush with front timing chain case end face using suitable drift [outer diameter: 60 mm (2. PBIC2615E 2. • Apply new engine oil to both oil seal lip and dust seal lip. Install idler pulley. • Install it so that each seal lip is oriented as shown. "Recommended Chemical Products and Sealants".

A Use Genuine RTV Silicone Sealant or equivalent. Assemble front timing chain case as follows: I J PBIC2548E K i. From the fitting point. Apply a continuous bead of liquid gasket using a suitable tool to front timing chain case back side as shown. c. CAUTION: H Do not reuse O-rings. L M N PBIC1100E ii. PBIC2915E Revision: August 2014 EM-173 2015 Frontier NAM . EM C D E F G PBIC2913E b. insert dowel pin while holding front P timing chain case from front and top completely. FRONT TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] a. iii. O tighten bolts temporarily while holding front timing chain case from front and top as shown. make entire front timing chain case contact rear timing chain case completely. Since front timing chain case is offset for difference of bolt holes. "Recommended Chemical Products and Sealants". Refer to GI-21. Same as the previous step. Fit lower end of front timing chain case tightly onto top face of oil pan (upper). Install new O-rings on rear timing chain case.

Bolt position Bolt diameter 1-5 : 10 mm (0.39 in) 6 – 25 : 6 mm (0. SBIA0492E c.0 N·m (5. Install new collared O-rings in front timing chain case oil hole (left and right sides). PBIC2631E d. Refer to GI-21. • There are two type of bolts. retighten them to the specified torque in numerical order as shown. 16 ft-lb) PBIC2907E 7.24 in) PBIC2908E Bolt position Tightening specification 1-5 : 55.2 kg-m. Install right and left intake valve timing control covers as follows: a. e. align dowel pins on front timing chain case with the holes to install intake valve timing control covers. After all bolts are tightened. Revision: August 2014 EM-174 2015 Frontier NAM . Front oil pan bolt : 22. b. "Recommended Chemical Products and Sealants".7 N·m (1. FRONT TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] d.0 N·m (2. Install two bolts in front of oil pan (upper) in numerical order as shown. CAUTION: Do not reuse O-rings. Being careful not to move seal ring from the installation groove.6 kg-m. Apply a continuous bead of liquid gasket using a suitable tool to intake valve timing control covers as shown.3 kg-m. 41 ft-lb) 6 – 25 : 12. Install new seal rings in shaft grooves. 9 ft-lb) 6. Use Genuine RTV Silicone Sealant or equivalent. Tighten bolts to the specified torque in numerical order as shown.

J • Use procedure below to check for fuel leakage. Installation of the remaining components is in the reverse order of removal. Install crankshaft pulley. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns H smoothly. G Tool number : KV11105210 (J-44716) 9. Noise will stop after hydraulic pressure rises. K • Start engine. if necessary. Refer to MA-16. fill to the specified level. Revision: August 2014 EM-175 2015 Frontier NAM . E b. FRONT TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] e. 10. Refill to spec- ified level. N • Summary of the inspection items: Item Before starting engine Engine running After engine stopped O Engine coolant Level Leakage Level Engine oil Level Leakage Level A/T and CVT Models Leakage Level/Leakage Leakage P Transmission/ transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage Other oils and fluids* Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas — Leakage — *Power steering fluid. Remove Ring Gear Stopper Tool. With fuel pressure applied to fuel piping. With engine speed increased. such as in cooling system. • Bleed air from passages in lines and hoses. this is normal. • After cooling down engine. brake fluid. A EM C PBIC0918E D 8. • Run engine to check for unusual noise and vibration. Tighten crankshaft pulley bolt in two steps. again check oil/fluid levels including engine oil and engine coolant. • When press-fitting crankshaft pulley with plastic hammer.90° degrees clockwise c. check oil/fluid levels including engine coolant and engine oil. check again for fuel leakage at connection points.1 N·m (4. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation. • Warm up engine thoroughly to make sure there is no leakage of fuel. INSPECTION AFTER INSTALLATION I • Before starting engine.5 kg-m. 33 ft-lb) F Step 2 : 84° . "FOR MEXICO : Fluids and Lubricants" (Mexico). Tighten bolts in numerical order as shown. • Turn ignition switch ON (with engine stopped). check for fuel leak- age at connection points. However. exhaust gas. Install crankshaft pulley as follows: a. tap on its center portion (not circumference). Step 1 : 44. If less than required quantity. or any oils/fluids including M engine oil and engine coolant. slack in the guide L may generate a pounding noise during and just after engine start. etc. taking care not to damage front oil seal. "FOR USA AND CANADA : Fluids and Lubricants" (United States and Canada) and MA-19.

Slack guide 10. Crankshaft sprocket 12. Camshaft sprocket (EXH) 5. Timing chain tensioner (secondary) (RH) 4. camshaft brackets. Camshaft sprocket RH (INT) 8. Timing chain (secondary) 6. do not turn the crankshaft and camshaft separately. oil seals. or the valves will strike the pistons. chain tensioners. and crankshaft pulley. Timing chain tensioner (primary) 11. or other sliding parts. O-ring 14. REMOVAL Revision: August 2014 EM-176 2015 Frontier NAM . • When installing camshafts. • Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets. NOTE: It is not necessary to remove the rocker covers or intake manifold collector to remove or install the timing chain(s). Internal chain guide 2. Timing chain (primary) 7. O-ring 3. Camshaft sprocket LH (INT) 9. Timing chain tensioner (secondary) (LH) 13. Tension guide Removal and Installation INFOID:0000000010709732 CAUTION: • After removing timing chains. lubricate contacting surfaces with new engine oil. TIMING CHAIN < REMOVAL AND INSTALLATION > [VQ40DE] TIMING CHAIN Exploded View INFOID:0000000010709731 AWBIA0859GB 1.

Remove timing chain (primary). 1 cylinder is at TDC of its compression stroke. J PBIC2919E 6. TIMING CHAIN < REMOVAL AND INSTALLATION > [VQ40DE] 1. NOTE: Use stopper pin included with Tool J-50246. • If not. Keep slack guide pressed and insert stopper pin through the tensioner body hole and plunger groove (3) to hold I plunger in. Remove front timing chain case. H 2. 4. Tool number : KV11105210 (J-44716) F • If the original timing chain markings are not legible. If removing the secondary timing chains. remove Ring Gear Stopper Tool and turn crankshaft clockwise 360° (one revolution). Remove internal chain guide. 3. Depress plunger into tensioner body by pressing slack guide (2). 1. CAUTION: Revision: August 2014 EM-177 2015 Frontier NAM . and release plunger stopper (1). Set No. loosen camshaft sprocket bolts. K L M N O P PBIC2266E 7. Refer to EM-168. E • Re-install Ring Gear Stopper Tool. EM C AWBIA0719ZZ D 2. G 5. "Removal and Installation". • Rotate crankshaft pulley clockwise to align timing mark (A) A (grooved line without color) with timing indicator (B). 3. Loosen clip of primary timing chain tensioner. 1 cylinder to TDC. Compress the primary timing chain tensioner. use paint or equivalent to mark the timing chains to the sprockets. Check timing chain markings to confirm No.

[Removing camshaft bracket (No. CAUTION: Be careful of plunger coming off when removing timing chain (secondary). Remove timing chain (secondary) together with camshaft sprockets.020 in)-thick metal or resin plate between tim- ing chain and timing chain tensioner plunger (guide). 9. PBIC1978E • When handling camshaft sprocket (INT). Remove crankshaft sprocket. be careful of the fol- lowing: CAUTION: • Handle carefully to avoid any shock to camshaft sprocket. Remove timing chain (secondary) and camshaft sprockets as follows: a. if necessary. PBIC2047E b. PBIC0282E INSTALLATION Revision: August 2014 EM-178 2015 Frontier NAM . • Insert 0. NOTE: • Use stopper pin included with Tool J-50246. (Do not loosen bolts (A) as shown). Attach stopper pin to the right and left timing chain tensioners (secondary). Remove camshaft sprocket (INT and EXH) bolts. Replace chain if necessary. • Do not disassemble.5 mm (0. c. 8. TIMING CHAIN < REMOVAL AND INSTALLATION > [VQ40DE] After removing timing chain (primary). refer to EM- 185. 1) is required.] PBIC2920E INSPECTION AFTER REMOVAL Check for cracks and any excessive wear at link plates. do not turn crankshaft and camshaft separately. NOTE: For removal of timing chain tensioner (secondary). "Removal and Installation (Secondary Timing Chain Ten- sioner)". • Inspect all timing chains and associated parts for wear or damage. or valves will strike the piston heads. replace as necessary. Remove timing chain (secondary) together with camshaft sprockets with timing chain loose from guide groove. • Turn camshaft slightly to secure slack of timing chain on timing chain tensioner (secondary) side. NOTE: Camshaft sprocket (INT) is a one piece integrated design with sprockets for timing chain (primary) and for timing chain (sec- ondary).

with the components installed. dowel pin of camshaft and crank- L shaft key are located as shown. Crankshaft key P : At cylinder head side of right bank. for the M placement of cam nose. Mating mark (back side) 17. TIMING CHAIN < REMOVAL AND INSTALLATION > [VQ40DE] A EM C D E F G H AWBIA1011GB 1. Make sure that dowel pin hole. Camshaft sprocket (intake) 3. Camshaft sprocket (exhaust) 9. Primary timing chain 14. Revision: August 2014 EM-179 2015 Frontier NAM . Tensioner guide 10. 1. 2. Confirm all mating mark positions repeatedly during the installation process. it is generally accepted camshaft is placed for the same direction of the figure. Secondary timing chain 8. Install timing chains (secondary) and camshaft sprockets as follows: CAUTION: Mating marks between timing chain and sprockets slip easily. Mating mark (blue link) 4. (No. Crankshaft sprocket 12. N Camshaft dowel pin hole (intake side) : At cylinder head upper face side in each bank. 1 cylinder at compression TDC) NOTE: Though camshaft does not stop at the position as shown. Primary timing chain tensioner J 16. Camshaft dowel pin (exhaust side) KBIA1073E O : At cylinder head upper face side in each bank. Water pump 11. Mating mark (copper link) I 7. Slack guide 15. Mating mark (notched) 13. Mating mark (punched) 5. Secondary timing chain tensioner 6. Crankshaft key NOTE: K The figure above shows the relationship between the mating mark on each timing chain and that on the corre- sponding sprocket. Internal chain guide 2.

• Left bank mating marks (6) • Align the timing chain mating marks (secondary) (2) (blue color link) with the ones on camshaft sprockets (INT and EXH) (4). Left bank : Use oval type (4) and (5). They should be used for the right and left banks. align pin hole on the small diameter side of the camshaft front end with dowel pin (3) on the back side of camshaft sprocket. Final tightening will be done with all timing chains installed. • On the intake side. use paint or equivalent to re-mark the camshaft sprockets at each mating mark. d. • Align dowel pin (3) and pin hole on camshafts with the groove (11) and dowel pin on sprockets. Right bank : Use circle type (7) and (10). NOTE: • Mating marks for camshaft sprocket (INT) are on the back side of camshaft sprocket (secondary). Push plunger of timing chain tensioner (secondary) and keep it pressed in with stopper pin. confirm mating marks are visible. (7) and (10) (punched). • Use stopper pin included with Tool J-50246. Tightening them by hand is enough to prevent the dislocation of dowel pins. (5) types. • In case that positions of each mating mark and each dowel pin WBIA0689E do not fit on mating parts. Install timing chains (secondary) (8) and camshaft sprockets [INT (1) and EXH (9)]. make fine adjustment to the position by slightly turning camshaft(s). SEM811G c. If necessary. • There are two types of mating marks. SEM430G b. • Bolts for camshaft sprockets must be tightened in the next step. Confirm the mating marks are aligned. align dowel pin on camshaft front end with pin groove (11) on camshaft sprocket. (10) and oval (4). circle (7). (5). respectively. and install them. Revision: August 2014 EM-180 2015 Frontier NAM . TIMING CHAIN < REMOVAL AND INSTALLATION > [VQ40DE] a. then finger tighten camshaft sprocket bolts. and install them. and install them. • On the exhaust side. Before installing timing chains (secondary) and camshaft sprockets. and install them.

Install the primary timing chain. TIMING CHAIN < REMOVAL AND INSTALLATION > [VQ40DE] e. • Install primary timing chain so the mating mark punched (B) on camshaft sprocket is aligned with the blue link (A) on the tim. I ing chain. • Make sure the mating marks on crankshaft sprocket face the E front of engine. • During alignment. while the mating mark notched (E) on the crankshaft sprocket (D) is aligned with the copper link (F) on the timing chain. J • When it is difficult to align mating marks (A) with (B) and (E) with (F) of the primary timing chain with each sprocket. as shown. L M N WBIA0721E O P Revision: August 2014 EM-181 2015 Frontier NAM . be careful to prevent dislocation of mating K mark alignments of the secondary timing chains. A EM C PBIC2110E D 3. Remove stopper pins out from timing chain tensioners (second- ary). gradu- ally turn the camshaft to align it with the mating marks. Install timing chain (primary) as follows: a. Install crankshaft sprocket. • Water pump (G). F G SEM929E H b.

check for fuel leak- age at connection points. Tighten camshaft sprocket bolts to specification with all timing chains installed and Tool holding the crank- shaft. 6. With engine speed increased. TIMING CHAIN < REMOVAL AND INSTALLATION > [VQ40DE] 4. Refer to MA-16. check again for fuel leakage at connection points. PBIC2109E • If removed. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation. 5. fill to the specified level. "FOR USA AND CANADA : Fluids and Lubricants" (United States and Canada). With fuel pressure applied to fuel piping. INSPECTION AFTER INSTALLATION • Before starting engine. If less than required quantity. Install internal chain guide. • Turn ignition switch ON (with engine stopped). Refer to EM-168. However. slack in the guide may generate a pounding noise during and just after engine start. reinstall slack guide. • Run engine to check for unusual noise and vibration. "FOR MEXICO : Fluids and Lubricants" (Mexico). check oil/fluid levels including engine coolant and engine oil. • Start engine. It is normal for a gap to exist under the bolt seats when bolts are tightened to specification. Noise will stop after hydraulic pressure rises. Install front timing chain case. Make sure again that the mating marks on camshaft sprockets and timing chain have not slipped out of alignment. Tool number : KV11105210 (J-44716) 7. this is normal. PBIC2633E • Remove stopper pin from primary timing chain tensioner. Refer to MA-19. Revision: August 2014 EM-182 2015 Frontier NAM . "Removal and Installation". CAUTION: Do not overtighten slack guide bolts. • Use procedure below to check for fuel leakage.

etc. or any oils/fluids including engine oil and engine coolant. F G H I J K L M N O P Revision: August 2014 EM-183 2015 Frontier NAM . Refill to spec- ified level. such as in cooling system. TIMING CHAIN < REMOVAL AND INSTALLATION > [VQ40DE] • Warm up engine thoroughly to make sure there is no leakage of fuel. • After cooling down engine. if necessary. brake fluid. again check oil/fluid levels including engine oil and engine coolant. A • Bleed air from passages in lines and hoses. exhaust gas. EM • Summary of the inspection items: Item Before starting engine Engine running After engine stopped C Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage D transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage Other oils and fluids* Level Leakage Level Fuel Leakage Leakage Leakage E Exhaust gas — Leakage — *Power steering fluid.

"Exploded View". Refer to EXT-15. Remove engine room cover using power tool. Camshaft sprocket RH (INT) 8. Remove coolant reservoir hose. Slack guide 10. Revision: August 2014 EM-184 2015 Frontier NAM . Timing chain (secondary) 6. Refer to EM-141. 4. Disconnect mass air flow sensor and remove air cleaner case (upper). Disconnect crankcase ventilation hose and remove air duct and resonator assembly. Refer to EM-140. "Removal and Installation". "Removal and Installation". 8. Tension guide Removal and Installation (Primary Timing Chain Tensioner) INFOID:0000000010709734 REMOVAL NOTE: When removing components such as hoses. "Removal and Installation". "Removal and Installation". Internal chain guide 2. O-ring 14. 6. Partially drain engine coolant. Timing chain (primary) 7. Camshaft sprocket (EXH) 5. Refer to CO-44. Timing chain tensioner (secondary) (RH) 4. 10. 5. Crankshaft sprocket 12. 7. Remove upper fan shroud.. Refer to CO-40. O-ring 3. 9. Remove engine under cover (if equipped). cap or plug openings to prevent fluid from spill- ing. etc. Camshaft sprocket LH (INT) 9. 2. "Changing Engine Coolant". Refer to CO-48. 1. TIMING CHAIN TENSIONER < REMOVAL AND INSTALLATION > [VQ40DE] TIMING CHAIN TENSIONER Exploded View INFOID:0000000010709733 AWBIA0859GB 1. "Removal and Installation (Motor driven type)". Remove lower fan shroud. Disconnect upper radiator hose from radiator. Timing chain tensioner (primary) 11. tubes/lines. Refer to EM-141. 3. Refer to CO-44. Disconnect and remove engine cooling fan (Motor driven type). Timing chain tensioner (secondary) (LH) 13. "Exploded View".

push in plunger and keep it pressed in with stopper pin. Remove the rocker covers. "Removal and Installation (Secondary Timing P Chain Tensioner)". Remove timing chain tensioner (primary) as follows: EM a. • When installing timing chain tensioner (primary). 1). Remove the timing chains (secondary). Remove drive belt auto-tensioner. "Drive Belt Auto-Tensioner and Idler Pulley". Remove the camshaft brackets (No. Depress plunger into tensioner body by pressing slack guide (2). G H PBIC2836E I INSTALLATION Installation is in the reverse order of removal. Refer to EM-130. "Removal and Installation". 12. Remove the timing chains (primary) and (secondary). b. F CAUTION: Be careful not to drop timing chain tensioner bolts inside timing chain case. "Removal and Installation". • Use stopper pin included with Tool J-50246. Loosen clip of timing chain tensioner (primary). pull out stopper pin. "Removal and Installation". Remove timing chain tensioner bolts and remove timing chain tensioner (primary). 2. 14. Revision: August 2014 EM-185 2015 Frontier NAM . Refer to EM-193. Refer to EM-129. Refer to EM-185. D E PBIC2835E d. Remove the secondary timing chain tensioners. Removal and Installation (Secondary Timing Chain Tensioner Shoe) INFOID:0000000010709736 O REMOVAL 1. Remove chain tensioner cover. Keep slack guide pressed and insert stopper pin through the tensioner body hole and plunger groove (3) to hold plunger in. M 3. J • Remove any dirt and foreign materials completely from the back and the mounting surfaces of primary tim- ing chain tensioner. N INSTALLATION Installation is in the reverse order of removal. Remove drive belt. TIMING CHAIN TENSIONER < REMOVAL AND INSTALLATION > [VQ40DE] 11. Refer to EM-158. "Removal and Installation". C c. Refer to EM-176. and release plunger stopper (1). 4. A 13. • After installation. K Removal and Installation (Secondary Timing Chain Tensioner) INFOID:0000000010709735 L REMOVAL 1.

TIMING CHAIN TENSIONER < REMOVAL AND INSTALLATION > [VQ40DE] 2. Installation of the remaining components is in the reverse order of removal. • Tighten the bolt until the secondary timing chain tensioner shoe is fully seated on the secondary timing chain tensioner. Remove the secondary timing chain tensioner shoe by evenly prying at base of shoe with suitable tool as shown. ALBIA0677ZZ Revision: August 2014 EM-186 2015 Frontier NAM . CAUTION: Do not overtighten bolt. Tool number : — (J-50246) 2. Install new secondary timing chain tensioner shoe using Tool (A) as shown. ALBIA0676ZZ INSTALLATION 1.

if necessary. N 3. "Removal and Installation". 4. Remove water pump. do not turn the crankshaft and camshaft separately. REMOVAL M 1. Refer to EM-151. "Removal and Installation". Remove rear timing chain case as follows: P Revision: August 2014 EM-187 2015 Frontier NAM . 2. Refer to EM-168. • Be careful not to damage sensor edges. O 5. "Removal and Installation (Secondary Timing Chain Tensioner)". Refer to EM-176. Refer to installation Removal and Installation INFOID:0000000010709738 K CAUTION: • After removing timing chain. Remove front timing chain case. O-rings J 4. or the valves will strike the pistons. L • Before removing the upper oil pan. Cylinder block A. Remove timing chains and related components. Refer to CO-50. Water drain plug (front) 3. remove the crankshaft position sensor (POS). Rear timing chain case 2. Remove oil pan (lower) and (upper). "Removal and Installation" and EM- 185. REAR TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] REAR TIMING CHAIN CASE A Exploded View INFOID:0000000010709737 EM C D E F G H I AWBIA0860GB 1. "Removal and Installation".

Cut liquid gasket using Tool and remove rear timing chain case. CAUTION: Do not reuse O-rings. Loosen and remove bolts using power tool in reverse order as shown. Remove O-rings from cylinder block. b. • After removal. Remove O-rings from cylinder head and camshaft bracket (No. handle rear timing chain case carefully so it does not twist. PBIC0788E Revision: August 2014 EM-188 2015 Frontier NAM . SBIA0496E 7. PBIC2921E CAUTION: • Do not remove plate metal cover of oil passage. REAR TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] a. PBIC2922E 6. 1). bend. Tool number : KV10111100 (J-37228) CAUTION: Do not damage the mating surfaces. or warp under a load. CAUTION: Do not reuse O-rings.

Install new O-rings onto cylinder block. Use scraper to remove all traces of old liquid gasket from rear timing chain case. E F G PBIC2084E INSTALLATION H 1. and opposite mating surfaces. "Recommended Chemical Prod- ucts and Sealants". completely wipe off liquid gasket covering the area shown. Refer to GI-21. 1). Revision: August 2014 EM-189 2015 Frontier NAM . REAR TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] 8. CAUTION: I Do not reuse O-rings. Install new O-rings to cylinder head and camshaft bracket (No. P Use Genuine RTV Silicone Sealant or equivalent. Install rear timing chain case as follows: a. N O SBIA0496E c. CAUTION: M Do not reuse O-rings. A EM C PBIC2910E D • Remove old liquid gasket from bolt hole and thread. Apply liquid gasket using a suitable tool to rear timing chain case back side as shown. CAUTION: • For “A”. J K PBIC0788E L b.

Align rear timing chain case with dowel pins (right and left) on cylinder block and install rear timing chain case. Tighten bolts in numerical order as shown.63 in) f. retighten them to the specified torque in numerical order as shown.7 N·m (1. 8. 3. 9 ft-lb) (0. After all bolts are tightened. cylinder head and camshaft bracket (No.0 N·m (1.3 kg-m. 9 ft-lb) (0.3 kg-m. 10 16 mm 4. 7. 2. wipe it off immediately. • There are two type of bolts with different torque specifications.63 in) 16 mm 12 through 26 : 15. • If liquid gasket protrudes. 11 : 12. : 12. CAUTION: Do not reuse O-rings. 6.7 N·m (1. Refer to the following for installing bolts. REAR TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] • Apply liquid gasket on installation position of water pump and cylinder head very completely. 11 ft-lb) PBIC2921E (0. Revision: August 2014 EM-190 2015 Frontier NAM .5 kg-m. PBIC2924E d.79 in) 9. 1). Bolt length Bolt position Torque specification 20 mm 1. 5. e. • Make sure O-rings stay in place during installation to cylinder block.

Install timing chains and related components. However. such as in cooling system. if necessary. E 3. • Use procedure below to check for fuel leakage. • Summary of the inspection items: L Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level M Engine oil Level Leakage Level Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage N Other oils and fluids* Level Leakage Level Fuel Leakage Leakage Leakage O Exhaust gas — Leakage — *Power steering fluid. With fuel pressure applied to fuel piping. Refer to EM-168.0055 in) • If not within the standard. K • After cooling down engine. REAR TIMING CHAIN CASE < REMOVAL AND INSTALLATION > [VQ40DE] g. If less than required G quantity. check again for fuel leakage at connection points. Install front timing chain case.14 mm (–0. Refer to MA-16. or any oils/fluids including engine oil and engine coolant. Refill to spec- ified level. "Removal and Installation".0094 to 0. Install water pump with new O-rings. After installing rear timing chain case. "Removal and Installation". check the surface height difference between following parts on oil pan (upper) mounting A surface. repeat the installation procedure. Refer to EM-176. slack in the guide may generate a pounding noise during and just after engine start. C PBIC2925E D 2. exhaust gas. fill to the specified level. With engine speed increased. INSPECTION AFTER INSTALLATION • Before starting engine. Refer to MA-19. • Bleed air from passages in lines and hoses. check oil/fluid levels including engine coolant and engine oil. 4. Standard EM Rear timing chain case to lower cylinder block: –0. I NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation. • Start engine. "Removal and Installation". if removed. Refer to EM-151. "Removal and Installation" and EM-185. P Revision: August 2014 EM-191 2015 Frontier NAM . check for fuel leak- age at connection points. again check oil/fluid levels including engine oil and engine coolant. etc. Noise will stop J after hydraulic pressure rises. F 5. CAUTION: Do not reuse O-rings. • Run engine to check for unusual noise and vibration. Install oil pan (upper) and (lower). • Warm up engine thoroughly to make sure there is no leakage of fuel. this is normal. H • Turn ignition switch ON (with engine stopped). Refer to CO-50. brake fluid. "FOR USA AND CANADA : Fluids and Lubricants" (United States and Canada). "Removal and Installation (Secondary Timing Chain Tensioner)". "FOR MEXICO : Fluids and Lubricants" (Mexico).24 to 0.

Camshaft bracket (No. CAMSHAFT < REMOVAL AND INSTALLATION > [VQ40DE] CAMSHAFT Exploded View INFOID:0000000010709739 PBIC2930E Intake valve timing control solenoid 1. 11. Intake valve timing control solenoid valve (LH bank) Revision: August 2014 EM-192 2015 Frontier NAM . Dowel pin 8. Plunger (RH bank) Timing chain tensioner (secondary) 13. Gasket 3. 1) 7. 18. Camshaft (EXH) 5. 2 to 4) valve (RH bank) 4. Spring 12. 14. Camshaft bracket (No. 2. (RH bank) (LH bank) 19. O-ring 17. Valve lifter 9. O-ring Timing chain tensioner (secondary) 10. Cylinder head (LH bank) (LH bank) Camshaft position sensor (PHASE) Camshaft position sensor (PHASE) 16. Camshaft (INT) 6. Cylinder head (RH bank) 15.

• Do not place sensors in a location where they are exposed to magnetism. CAMSHAFT < REMOVAL AND INSTALLATION > [VQ40DE] Removal and Installation INFOID:0000000010709740 A REMOVAL 1. 3. Remove front timing chain case. G KBIA1046E H 9. 4. Release the fuel pressure. • Discard intake valve timing control solenoid valve gaskets and use new gaskets for installation. Refer to WT-48. Remove rocker covers. 7. camshaft brackets and bolts so they are placed in the same position and direction for L installation. Remove intake manifold collector. Remove front fender protectors. "Removal and Installation". 6. M N O P Revision: August 2014 EM-193 2015 Frontier NAM . E CAUTION: • Handle carefully to avoid dropping and shocks. Refer to EM-142. camshaft sprockets. I J K WBIA0169E 10. Refer to EM-158. Refer to PG-89. Remove front wheels and tires. • Do not allow metal powder to adhere to magnetic part at F sensor tip. "Removal and Installation". Refer to EC-968. "Removal and Installation". timing chains and rear timing chain case. "Removal and Installation" and EM-187. "Removal and Installation of Front Fender Protector". C 5. Remove camshaft position sensor (PHASE) (right and left banks) from cylinder head back side. "Removal and Installation". • Mark camshafts. Refer to EXT-27. 8. Disconnect the battery negative terminal. Refer to D EM-176. • Do not disassemble. Remove intake valve timing control solenoid valves. "Adjustment". Remove camshaft brackets. EM 2. "Fuel Pressure Check".

(Total indicator reading) Standard : Less than 0. Remove camshafts. replace camshaft. • Identify installation positions. CAUTION: Do not support journal No.05 mm (0. Turn camshaft to one direction with hands. 2. Remove valve lifters. and store them without mixing them up. 12. PBIC2111E INSPECTION AFTER REMOVAL Camshaft Runout 1. NOTE: Stopper pin was attached when timing chain (secondary) was removed. Remove timing chain tensioner (secondary) from cylinder head. 13. 1 (on the side of camshaft sprocket) because it has a different diameter from the other three locations. CAMSHAFT < REMOVAL AND INSTALLATION > [VQ40DE] • Equally loosen camshaft bracket bolts in several steps in reverse order as shown. and measure the camshaft runout on dial indicator. PBIC2050E 11. Put V-block on precise flat table. 3 journal. if necessary. 2 and 4 journal of camshaft. If it exceeds the limit. Camshaft Cam Height Revision: August 2014 EM-194 2015 Frontier NAM .02 mm (0. • Remove timing chain tensioner (secondary) with its stopper pin attached. 3. Set dial indicator vertically to No.0008 in) PBIC0929E Limit : 0. and support No.0020 in) 4.

replace either or both camshaft and cylinder head.445 . NOTE: Camshaft bracket cannot be replaced as a single part. 1 : 25. EMQ0072D D Camshaft Journal Oil Clearance CAMSHAFT JOURNAL DIAMETER • Measure the outer diameter of camshaft journal with micrometer.9238 in) G PBIC0040E H CAMSHAFT BRACKET INNER DIAMETER • Tighten camshaft bracket bolt with the specified torque.0059 in) O • If the calculated value exceeds the limit. because it is machined together with cylinder head. I • Measure the inner diameter “A” of camshaft bracket with bore gauge.9230 .15 mm (0.1.045 .075 .1.000 .26.7821 in) C Exhaust : 44. Measure the camshaft cam height with micrometer. P Replace whole cylinder head assembly.655 mm (1.23.0.0211 .0030 in) Limit : 0.0.7821 in) Limit: Intake : 45. Standard: J No. A Standard: Intake : 45.465 mm (0.265 mm (1.035 . Camshaft End Play Revision: August 2014 EM-195 2015 Frontier NAM . 1 : 26. If wear exceeds the limit.9260 in) K L PBIC1645E CAMSHAFT JOURNAL OIL CLEARANCE • (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter).7746 . 4 : 23.0.0034 in) N No.0. CAMSHAFT < REMOVAL AND INSTALLATION > [VQ40DE] 1.875 mm (1.0218 in) F No.7974 in) EM Exhaust : 45.500 . 4 : 23. 3.521 mm (0.465 . 2.7900 .086 mm (0. 3.9252 . 4 : 0.0.265 mm (1. M Standard: No.0236 .25. 3. 2.076 mm (0.1. E Standard: No.7667 in) 2. 2.45.0014 .0244 in) No. 1 : 0. replace camshaft.1.23.955 mm (1.45.0.0018 .935 .021 mm (1.

115 .360 . Measure the end play of dial indicator when camshaft is moved for- ward/backward (in direction to axis). 1 journal Standard : 27.0094 in) SEM864E • Measure the following parts if out of the limit.1. Refer to EM-248. replace camshaft and/or cylinder head. KBIA0182E Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER Revision: August 2014 EM-196 2015 Frontier NAM .0045 . KBIA2404J Camshaft Sprocket Runout 1.0059 in) • If it exceeds the limit. 2 and 4 journal of camshaft.0. Put V-block on precise flat table.27.188 mm (0. and support No. CAMSHAFT < REMOVAL AND INSTALLATION > [VQ40DE] • Install dial indicator in thrust direction on front end of camshaft.Dimension “A” for camshaft No.500 .24 mm (0. 2. Measure the camshaft sprocket runout with dial indicator.548 mm (1. • If anything above is found.0846 in) .15 mm (0.27. (Total indicator reading) Limit : 0.0827 . "Standard and Limit". CAUTION: Do not support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other three locations. Standard : 0.0772 . . replace valve lifter.Dimension “B” for cylinder head No.0781 in) • Following the standards above. replace camshaft sprocket. 1 journal bearing Standard : 27.385 mm (1. PBIC0930E Valve Lifter Check if surface of valve lifter has any wear or cracks.0.0074 in) Limit : 0.1.

M • Install new O-rings as shown. replace either or both valve lifter and cylinder head.3381 in) EM C JEM798G D VALVE LIFTER HOLE DIAMETER • Measure the inner diameter of valve lifter hole of cylinder head with inside micrometer. • Install timing chain tensioner with its stopper pin attached. "Stan- dard and Limit".0.3392 in) F G SEM867E H VALVE LIFTER CLEARANCE • (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter). Install valve lifters.0015 in) J • If the calculated value is out of the standard.33.0005 .1.016 mm (1.039 mm (0.0. Refer to EM-248. N PBIC2111E 2. I Standard (Intake and exhaust) : 0. A Standard (Intake and exhaust) : 33. CAMSHAFT < REMOVAL AND INSTALLATION > [VQ40DE] • Measure the outer diameter at 1/2 height of valve lifter with micrometer since valve lifter is in barrel shape. E Standard (Intake and exhaust) : 34.34. 3. O • Install it in the original position. INSTALLATION K 1.013 . Install timing chain tensioners (secondary) on both sides of cyl- inder head.000 .987 mm (1. referring to each standard of valve lifter outer diameter and valve lifter hole diameter.977 . P Revision: August 2014 EM-197 2015 Frontier NAM . CAUTION: Do not reuse O-rings. Install camshafts. and with sliding part facing upward on left-side cylinder head.3377 .3386 . L • Install timing chain tensioner with sliding part facing downward on right-side cylinder head.1.

Face small dia. KBIA1071E • Follow your identification marks made during removal. CAMSHAFT < REMOVAL AND INSTALLATION > [VQ40DE] • Install camshaft with dowel pin attached to its front end face on the exhaust side. it is generally accepted cam- shaft is placed for the same direction as shown. (No. or fol- low the identification marks that are present on new camshafts for proper placement and direction. • Though camshaft does not stop at the portion as shown. for the placement of cam nose. at intervals of 180°. PBIC2478E Revision: August 2014 EM-198 2015 Frontier NAM . side pin hole upward (in cylinder head upper face direction). Paint marks Identification Bank INT/EXH Dowel pin M1 M2 mark INT No Green No RE RH EXH Yes No White RE INT No Green No LH LH KBIA1009E EXH Yes No White LH • Install camshaft so that dowel pin hole and dowel pin on front end face are positioned as shown. 1 cylinder TDC on its compression stroke) NOTE: • Large and small pin holes are located on front end face of camshaft (INT).

2 to 4) aligning the stamp marks H as shown. Install camshaft brackets. 1). • Remove foreign material completely from camshaft bracket A backside and from cylinder head installation face. 1) as shown on right and left banks. NOTE: There are no identification marks indicating left and right for camshaft bracket (No. CAMSHAFT < REMOVAL AND INSTALLATION > [VQ40DE] 4. I J PBIC2052E K • Apply liquid gasket to mating surface of camshaft bracket (No. "Recommended Chemical Products and Sealants". • Install camshaft bracket in original position and direction as shown. L Use Genuine RTV Silicone Sealant or equivalent. EM C D E F G PBIC2051E • Install camshaft brackets (No. Refer to GI-21. M N O P PBIC2660E Revision: August 2014 EM-199 2015 Frontier NAM .

Camshaft bracket bolts Step 1 (bolts 7 .6 kg-m.88 N·m (0. CAUTION: • Perform this inspection only when DTC P0011 or P0021 are detected in self-diagnostic results of CONSULT and it is directed according to inspection procedure of EC section.4 N·m (1. 2. Release fuel pressure. 3. "Fuel Pressure Check". re-install cam- shaft bracket (No. "DTC Confirmation Procedure". 1) and cylinder head. Disconnect harness connectors from ignition coil and injector . INSPECTION AFTER INSTALLATION Inspection of Camshaft Sprocket (INT) Oil Groove WARNING: • Check when engine is cold so as to prevent burns from any splashing engine oil. Check the engine oil level. Refer to EC-623.2 kg-m. 52 in-lb) Step 4 (bolts 1 .96 N·m (0. Standard : –0. in numeri- cal order as shown.0055 in) • Measure two positions (both intake and exhaust side) for a single bank. 1).14 mm (–0. Tighten camshaft bracket bolts in the following steps. Installation of the remaining components is in the reverse order of removal. 1. Remove intake valve timing control solenoid valve. "Removal and Installation". b. "Inspection". 92 in-lb) PBIC2050E 6. Refer to EM-248.96 N·m (0. CAMSHAFT < REMOVAL AND INSTALLATION > [VQ40DE] 5. Refer to LU-22. Perform the following procedure so as to prevent the engine from being unintentionally started while checking.2 kg-m. Refer to EC-968. "Standard and Limit". 17 in-lb) Step 2 (bolts 1 . • If the measured value is out of the standard. EMQ0044D 7. Check and adjust the valve clearance. 8.0055 to 0.14 to 0.10) : 5.10) : 1.1 kg-m.6) : 1. a. Measure the difference in levels between front end faces of camshaft bracket (No. Refer to EM-168. Revision: August 2014 EM-200 2015 Frontier NAM . 17 in-lb) Step 3 (bolts 1 .10) : 10.

check for fuel leak- age at connection points. or any oils/fluids including engine oil and engine coolant. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT). slack in the guide J may generate a pounding noise during and just after engine start. Use a C shop cloth to prevent the engine components and the vehicle. "Lubrication Circuit". Refer to MA-16. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation. fill to the specified level. • Clean oil groove if necessary. WARNING: • Be careful not to touch rotating parts (drive belts. installation of the remaining components is in the reverse order of removal. With engine speed increased. Noise will stop after hydraulic pressure rises. exhaust gas. "System E Chart". H • Use procedure below to check for fuel leakage. A ing. LU-21. • Turn ignition switch ON (with engine stopped). L • Summary of the inspection items: Item Before starting engine Engine running After engine stopped M Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage N transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage Other oils and fluids* Level Leakage Level O Fuel Leakage Leakage Leakage Exhaust gas — Leakage — *Power steering fluid. 1) oil hole. Crank the engine. check oil/fluid levels including engine coolant and engine oil. etc. F 6. However. this is normal. CAUTION: • Engine oil may squirt from intake valve timing control solenoid valve installation hole during cranking. • After cooling down engine. • Warm up engine thoroughly to make sure there is no leakage of fuel. Refer to LU-21. P Revision: August 2014 EM-201 2015 Frontier NAM . CAMSHAFT < REMOVAL AND INSTALLATION > [VQ40DE] 4. LU-21. Refer to LU-21. • Start engine. • Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not come out from camshaft bracket (No. Immediately wipe off any splashed engine oil. idler EM pulley. After inspection. INSPECTION AFTER INSTALLATION G • Before starting engine. "FOR MEXICO : Fluids and Lubricants" (Mexico). "Lubrication Circuit". K • Bleed air from passages in lines and hoses.). Refill to spec- ified level. 1) oil hole. and crankshaft pulley. I • Run engine to check for unusual noise and vibration. 5. PBIC2869E • Do not allow engine oil to get on rubber components such D as drive belt or engine mount insulators. again check oil/fluid levels including engine oil and engine coolant. With fuel pressure applied to fuel piping. brake fluid. such as in cooling system. if necessary. and then make sure that engine oil comes out from camshaft bracket (No. check again for fuel leakage at connection points. End cranking after check. "FOR USA AND CANADA : Fluids and Lubricants" (United States and Canada). "System Chart". and then check each oil groove for clogging. etc. If less than required quantity. Refer to MA-19.

"Removal and Installation (Crankshaft driven type)". Refer to EM-168. 2. Refer to EM-129. Installation of the remaining components is in the reverse order of removal. Refer to EXT-15. 4. Refer to EM-193. WBIA0578E 5. Remove valve collet with magnet hand. OIL SEAL < REMOVAL AND INSTALLATION > [VQ40DE] OIL SEAL Removal and Installation of Valve Oil Seal INFOID:0000000010709741 REMOVAL 1. Remove camshaft relating to valve oil seal to be removed.3 . CAUTION: When working. adapter. 2.0. "Removal and Installation". Intake and exhaust : 14. 3. "Removal and Installation". Tool number : — (J-39386) NOTE: Dimension (H): height measured before valve spring seat instal- lation. Apply new engine oil to new valve oil seal joint surface and seal lip. Turn crankshaft until the cylinder requiring new oil seals is at TDC. Remove crankshaft pulley.9 mm (0. Remove valve oil seal using Tool.587 in) 3. "Removal and Installation".563 . Refer to EM-193. Tool number : KV10107902 (J-38959) WBIA0489E INSTALLATION 1.14. This will prevent valve from dropping into cylinder. "Removal and Installation". Refer to CO-47. Remove valve collet. 3. Press in valve oil seal to specified height (H) using Tool. Remove drive belt. take care not to damage valve lifter holes. "Removal and Installation". 2. WBIA0490E Removal and Installation of Front Oil Seal INFOID:0000000010709742 REMOVAL 1. Remove engine under cover (if equipped). Tool numbers : KV10116200 (J-26336-B) : KV10115900 (J-26336-20) : KV10109220 ( — ) • Compress valve spring using Tool attachment. Revision: August 2014 EM-202 2015 Frontier NAM . 4. Remove engine cooling fan assembly. Remove valve lifters. valve spring retainer and valve spring using Tool.

. "Removal and Installation from Vehicle (For 2WD Mod. CAUTION: A Be careful not to damage front timing chain case and crank- shaft. Install front oil seal. TM-74. Remove transmission assembly. "Removal and Installation from Vehicle (For 4WD Models)" (4WD models). Remove front oil seal using suitable tool. OIL SEAL < REMOVAL AND INSTALLATION > [VQ40DE] 5. N els)" (2WD models). E • Install front oil seal so that each seal lip is oriented as shown. Removal and Installation of Rear Oil Seal INFOID:0000000010709743 M REMOVAL 1. Refer to EM-219. CAUTION: J • Be careful not to damage front timing chain case and crankshaft. 2. 3. inner diameter 50 mm (1. EM C PBIC2931E D INSTALLATION 1. P PBIC2932E Revision: August 2014 EM-203 2015 Frontier NAM . Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal. 2. Remove rear oil seal with a suitable tool. PBIC2931E L 3. • Press-fit straight and avoid causing burrs or tilting oil K seal.Suitable drift: outer diameter 60 mm (2. Remove drive plate. "Exploded View".36 in). O CAUTION: Be careful not to damage crankshaft and cylinder block. I ing surface using suitable tool. Installation is in the reverse order of removal after this step. F G H SEM715A • Press-fit until the height of front oil seal is level with the mount. Refer to TM-72.97 in).

Installation of the remaining components is in the reverse order of removal. SEM715A • Install new rear oil seal using Tool. • Press-fit oil seal straight to avoid causing burrs or tilt- ing. oil leaks or breakage of drivetrain components. PBIC2933E • Press in rear oil seal to the position as shown. • Do not touch grease applied onto oil seal lip. Revision: August 2014 EM-204 2015 Frontier NAM . • Improper alignment caused by missing dowels may cause vibration. OIL SEAL < REMOVAL AND INSTALLATION > [VQ40DE] INSTALLATION 1. Apply new engine oil to new rear oil seal joint surface and seal lip. 2. CAUTION: • When replacing an engine or transmission you must make sure the dowels are installed cor- rectly during reassembly. Install rear oil seal so that each seal lip is oriented as shown. Tool number : — (J-49815) : — (J-8092) CAUTION: • Be careful not to damage crankshaft and cylinder block. SBIA0281E 3.

CYLINDER HEAD
< REMOVAL AND INSTALLATION > [VQ40DE]
CYLINDER HEAD
A
Exploded View INFOID:0000000010709744

EM

C

D

E

F

G

H

I
PBIC2934E

1. Rubber plug 2. Cylinder head (left bank) 3. Cylinder head bolt J
4. Cylinder head (right bank) 5. Harness bracket 6. Cylinder head gasket (right bank)
7. Cylinder head gasket (left bank)
K
Removal and Installation INFOID:0000000010709745

REMOVAL L
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing.
1. Remove camshaft. Refer to EM-193, "Removal and Installation". M
2. Remove intake manifold. Refer to EM-145, "Removal and Installation".
3. Remove exhaust manifold. Refer to EM-148, "Removal and Installation (Exhaust Manifold)".
N
4. Remove front final drive assembly (4WD models). Refer to DLN-191, "Removal and Installation".
5. Remove water inlet and thermostat assembly (left bank). Refer to CO-55, "Removal and Installation".
6. Remove water outlet, water pipe and heater pipe. Refer to CO-57, "Removal and Installation". O

P

Revision: August 2014 EM-205 2015 Frontier NAM

CYLINDER HEAD
< REMOVAL AND INSTALLATION > [VQ40DE]
7. Remove cylinder head bolts in reverse order as shown using
suitable tool and power tool to remove cylinder heads (right and
left banks).

PBIC2057E

8. Remove cylinder head gaskets.
INSPECTION AFTER REMOVAL
Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between (d1) and (d2)
exceeds the limit, replace the bolt with a new one.

Limit [(d1) - (d2)] : 0.11 mm (0.0043 in)
• If reduction of outer diameter appears in a position other than (d2),
use it as (d2) point.

PBIC2480E

Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-230, "Inspec-
tion After Disassembly".
1. Using suitable tool, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.
CAUTION:
Do not allow gasket fragments to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions.

Limit : 0.1 mm (0.004 in)
• If measured distortion exceeds the limit, replace cylinder head.

SEM861E

INSTALLATION

Revision: August 2014 EM-206 2015 Frontier NAM

CYLINDER HEAD
< REMOVAL AND INSTALLATION > [VQ40DE]
1. Install new cylinder head gasket.
2. Turn crankshaft until No. 1 piston is set at TDC. A
• Crankshaft key should line up with the right bank cylinder cen-
ter line as shown.
EM

C

SEM532G
D

3. Install cylinder head follow the steps below to tighten cylinder
head bolts in numerical order as shown. E
CAUTION:
If cylinder head bolts are re-used, check their outer diame-
ters before installation. Refer to EM-205, "Removal and
Installation" (Cylinder Head Bolts Outer Diameter). F

Step a : 98.1 N·m (10 kg-m, 72 ft-lb)
Step b : Loosen to 0 N·m in the reverse order of tight- G
ening.
Step c : 39.2 N·m (4.0 kg-m, 29 ft-lb)
H

I

J

K
PBIC2057E

Measure the tightening angle using Tool.
L
Tool number : KV10112100 (BT-8653-A)

Step d : 90° clockwise M
Step e : 90° clockwise
N

WBIA0581E
O

P

Revision: August 2014 EM-207 2015 Frontier NAM

CYLINDER HEAD
< REMOVAL AND INSTALLATION > [VQ40DE]
4. After installing cylinder head, measure distance between front
end faces of cylinder block and cylinder head (left and right
banks).

Standard : 14.1 - 14.9 mm (0.555 - 0.587 in)
• If the measured value is out of the standard, re-install cylinder
head.

EMQ0662D

5. Installation of the remaining parts is in the reverse order of removal.

INSPECTION AFTER INSTALLATION
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-16, "FOR USA AND CANADA : Fluids and Lubricants" (United
States and Canada). Refer to MA-19, "FOR MEXICO : Fluids and Lubricants" (Mexico).
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
after hydraulic pressure rises.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec-
ified level, if necessary.
• Summary of the inspection items:

Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level

Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage
transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gas — Leakage —
*Power steering fluid, brake fluid, etc.

Revision: August 2014 EM-208 2015 Frontier NAM

CYLINDER HEAD
< REMOVAL AND INSTALLATION > [VQ40DE]
Exploded View INFOID:0000000010709746

A

EM

C

D

E

F

G

H

PBIC2637E
I
1. Valve lifter 2. Valve collet 3. Valve spring retainer
4. Valve spring 5. Valve oil seal 6. Valve spring seat
7. Valve guide 8. Spark plug 9. Spark plug tube J
10. Cylinder head (right bank) 11. Valve seat 12. Valve (EXH)
13. Valve (INT) 14. Cylinder head (left bank)
K
Disassembly and Assembly INFOID:0000000010709747

DISASSEMBLY L
1. Remove spark plug.
2. Remove valve lifter.
• Identify installation positions, and store them without mixing them up. M
3. Remove valve collet.
• Compress valve spring and remove valve collet with magnet
hand using Tool. N
CAUTION:
When working, take care not to damage valve lifter holes.

Tool numbers : KV10109220 ( — ) O
: KV10116200 (J-26336-B)
: KV10115900 (J-26336-20) P
WBIA0578E

4. Remove valve spring retainer, valve spring and valve spring seat.
5. Push valve stem to combustion chamber side, and remove valve.
• Identify installation positions, and store them without mixing them up.

Revision: August 2014 EM-209 2015 Frontier NAM

Install valve spring (uneven pitch type). • Install narrow pitch end (paint mark) to cylinder head side (valve spring seat side). Revision: August 2014 EM-210 2015 Frontier NAM . 3.3 . When valve guide is removed. • Once removed. When valve seat is removed. • Using a suitable tool. WBIA0490E NOTE: Larger diameter valves are for intake side. "Inspection After Disassembly".9 mm (0. • Install it in the original position. "Inspection After Disassembly". If valve seat must be replaced. "Inspection After Disassembly". pull spark plug tube out of cylinder head. as necessary. Refer to EM-211. Tool number : — (J-39386) Height (H) (Without valve spring seat installed) Intake and exhaust : 14. 9. 2. spark plug tube will be deformed and cannot be reused. If valve guide must be replaced. Tool number : KV10107902 (J-38959) WBIA0489E 7. 8. "Inspection After Disassembly". Do not remove it unless absolutely necessary. CYLINDER HEAD < REMOVAL AND INSTALLATION > [VQ40DE] 6. Remove spark plug tube. ASSEMBLY 1. install it. Refer to EM-211.563 . Install valves.0. CAUTION: • Take care not to damage cylinder head. Install valve spring seat. 6. Install valve spring retainer. Refer to EM-211. install it. Remove valve oil seals using Tool.587 in) 4. 5. Refer to EM-211. Install valve oil seals using Tool.14. SEM085D 7.

• Install it in the original position.0.2350 in) P SEM938C Valve Guide Inner Diameter Measure the inner diameter of valve guide with inside micrometer.47 in) from edge of spark plug tube press-fit side. • Compress valve spring using Tool. replace valve and check the valve seat contact. CYLINDER HEAD < REMOVAL AND INSTALLATION > [VQ40DE] 8. • Press-fit spark plug tube as follows: a. K Inspection After Disassembly INFOID:0000000010709748 L VALVE DIMENSIONS • Check dimensions of each valve. Remove old liquid gasket adhering to cylinder head mounting hole.970 mm (0. Refer to EM-132.0. WBIA0578E • Tap valve stem edge lightly with plastic hammer after installa. N Standard Intake : 5.980 mm (0.2344 . Refer to GI-21. Press-fit spark plug tube so that its height (H) is as specified using suitable drift. H Standard press-fit height (H) : Refer to EM-108. D tion to check its installed condition. take care not to damage valve lifter holes or valve stems. G c. Install spark plug.5.5. Install valve lifter. 11. wipe off liquid gasket protruding onto PBIC2638E cylinder-head upper face.2348 .955 . Apply sealant to area within approximately 12 mm (0. Tool numbers : KV10109220 ( — ) EM : KV10116200 (J-26336-B) : KV10115900 (J-26336-20) CAUTION: C When working. Use Genuine High Strength Locking Sealant or equivalent. J • After press-fitting. Revision: August 2014 EM-211 2015 Frontier NAM . E 10. attachment and adapter A using Tool.965 . Install valve collet. F b. Install spark plug tube. 9. "Standard and Lim- it" I CAUTION: • When press-fitting. "Standard and Limit". • If dimensions are out of the standard. M VALVE GUIDE CLEARANCE Valve Stem Diameter Measure the diameter of valve stem with micrometer. Install valve collet with magnet hand. take care not to deform spark plug tube. "Recommended Chemi- cal Products and Sealants". Refer to EM-248. "Removal and Installation".2354 in) O Exhaust : 5.

4006 .003 in) Exhaust : 0.0.0012 .08 mm (0. heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil. Drive out valve guide with a press [under a 20 kN (2 ton. replace valve and/or valve guide.2369 in) Valve Guide Clearance (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).0021 in) Exhaust : 0. Valve guide clearance: Standard Intake : 0.020 .0.0 Imp ton) pressure] or hammer and suitable tool.063 mm (0.018 mm (0. CYLINDER HEAD < REMOVAL AND INSTALLATION > [VQ40DE] Standard Intake and Exhaust : 6.196 mm (0.2362 . When working.0008 . replace with oversized [0. VALVE GUIDE REPLACEMENT When valve guide is removed. SEM008A 2.030 .0. SEM931C 3.10.0.6. WARNING: Cylinder head contains heat.09 mm (0. 1. wear protec- tive equipment to avoid getting burned.008 in)] valve guide.0.0.004 in) • If the calculated value exceeds the limit.175 .4014 in) SEM932C Revision: August 2014 EM-212 2015 Frontier NAM . 2. Ream cylinder head valve guide hole using suitable tool. Valve guide hole diameter (for service parts): Intake and exhaust : 10.2 mm (0. To remove valve guide. 2.0025 in) Limit Intake : 0.2 US ton.053 mm (0.000 .

0. Set the machine depth stop to ensure this.496 . CYLINDER HEAD < REMOVAL AND INSTALLATION > [VQ40DE] 4. • Check if the contact area band is continuous all around the circum- M ference.5 mm (0.8 mm (0. replace with oversized [0. 1. E Projection “L” Intake and exhaust : 12. A EM C SEM008A D 5. perform this procedure. L • Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface. H Standard: Intake and exhaust I : 6. G SEM950E 6. Bore out old seat until it collapses.504 in) F WARNING: Cylinder head contains heat. grind to adjust valve fitting and check again.2369 in) J SEM932C K VALVE SEAT CONTACT • After confirming that the dimensions of valve guides and valves are within the specifications. Refer to EM-248.0. Apply reamer finish to valve guide using suitable tool.018 mm (0. Boring should not continue beyond the bottom face of the seat recess P in cylinder head. Revision: August 2014 EM-213 2015 Frontier NAM . If the contacting surface still has “NG” conditions even after the re-check.2362 .6 . wear protec- tive equipment to avoid getting burned.12.020 in)] valve seat. When working. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil. N SBIA0322E O VALVE SEAT REPLACEMENT When valve seat is removed. CAUTION: Prevent to scratch cylinder head by excessive boring.000 . Press valve guide from camshaft side to the dimensions as shown using suitable tool. • If not. replace valve seat.6. "Standard and Limit".

1. CAUTION: • Avoid directly touching cold valve seats. grind to adjust valve fitting. Finish seat to the specified dimensions using suitable tool. PBIC0080E VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD Revision: August 2014 EM-214 2015 Frontier NAM . press on the contacting surface all around the circumference to cut in a single drive. CAUTION: When using valve seat cutter. Ream cylinder head recess diameter for service valve seat. Provide valve seats cooled well with dry ice.5 mm (0. Improper pressure on with cutter or cutting many different times may result in staged valve seat.516 mm (1.2874 .1. Force fit valve seat into cylinder head. SEM795A 3.32. "Standard and Limit". Refer to EM-248. wear protective equipment to avoid getting burned. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil. 5. VALVE SPRING SQUARENESS • Set try square along the side of valve spring and rotate spring.083 in) • If it exceeds the limit. Check again for normal contact.716 mm (1. firmly grip cutter handle with both hands. Oversize [0.500 .700 . 7. Using compound. replace valve spring. CYLINDER HEAD < REMOVAL AND INSTALLATION > [VQ40DE] 2.020 in)] Intake : 38. SEM934C 6.2880 in) • Be sure to ream in circles concentric to valve guide center. Measure the maximum clearance between the top face of spring and try square. Limit : 2. SEM008A 4. Then.1 mm (0. WARNING: • Cylinder head contains heat.38.5157 . This will enable valve to fit correctly.5164 in) Exhaust : 32. When working.

8531 in) Installation height C : 37.9 kg.9 .00 mm (1.42.42 lb) D Height during valve open : 27.0 .95 lb) • If the installation load or load with valve open is out of the standard. CYLINDER HEAD < REMOVAL AND INSTALLATION > [VQ40DE] • Check valve spring pressure at the specified spring height. replace valve spring. A Standard: Intake and exhaust Free height EM : 47.19. F G H I J K L M N O P Revision: August 2014 EM-215 2015 Frontier NAM .07 mm (1.188 N (16.4567 in) Installation load SEM113 : 166 . 84 .20 mm (1.0709 in) E Load with valve open : 373 . 37 .421 N (38.2 kg.

LH engine mounting bracket (upper) 4. RH engine mounting insulator 9. LH heat shield plate 5. RH engine mounting bracket (lower) 8. • Place chocks at front and back of rear wheels. Revision: August 2014 EM-216 2015 Frontier NAM . Rear engine mounting insulator 4WD 2. • For engines not equipped with engine slingers. LH engine mounting bracket (lower) 7. LH engine mounting insulator 6. RH heat shield plate 10. RH engine mounting bracket (upper) Removal and Installation INFOID:0000000010709750 WARNING: • Situate vehicle on a flat and solid surface. Rear engine mounting insulator 2WD 3. ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > [VQ40DE] UNIT REMOVAL AND INSTALLATION ENGINE ASSEMBLY Exploded View INFOID:0000000010709749 AWBIA0721GB 1. attach proper slingers and bolts described in PARTS CATALOG.

N 20. 14. Refer to LU-23. Disconnect EVAP line. "Removal and Installation". ensure that the front and rear of the vehicle are well balanced. • Do not start working until exhaust system and engine coolant are cooled sufficiently. Remove three way catalyst. G 4.. Remove engine under cover (if equipped). Refer to GI-33. "Removal and Installation (Three Way Catalyst)". Reposition the reservoir tank for power steering from engine compartment and move it aside. "Removal and Installation". Disconnect the fuel hose at the engine side connection. Refer to CO-44. J 12. 16. in C preparation for the backward shift of center of gravity. Remove the A/C compressor bolts and reposition the A/C compressor. Refer to EXT-15. "Removal I and Installation". Refer to PG-89. 13. Refer to EXT-23. "Removal and Installation of Hood Assembly". Remove the A/T oil level indicator and indicator tube. 5. Remove front final drive assembly (4WD models). O 23. Disconnect the engine room harness from the engine side and set it aside. avoid forceful or uninstructed operations. "Removal and Installation for Compressor". "Removal and Installation". Disconnect the battery negative terminal. Remove engine room cover using power tool. Disconnect brake booster vacuum hose between vehicle and engine and set it aside. "Removal and Installation". • Use either 2-point lift type or separate type lift. follow the procedures in the applica- EM ble sections. Remove engine oil filter. Remove the air duct and resonator assembly and air cleaner case assembly. "Removal and Installation". "Fuel Pressure Check". P Revision: August 2014 EM-217 2015 Frontier NAM . 8. Refer to CO-47. "Removal and Installation". Remove the engine hood. Disconnect the engine harness grounds. "Removal and Installation (Crankshaft driven K type)". support the rear axle jacking point with transmission jack or similar tool before starting work. "Changing Engine Coolant". Refer to EM-147. Remove the drive belts. Remove the engine cooling fan and shroud. H 7. Move it from its location and secure with a rope. Disconnect the heater hoses at cowl. Refer to EM-141. Disconnect power steering oil pump from engine. 19. 6. Refer to DLK-129. 9. Remove the radiator assembly and hoses. Refer to HA-25. Refer to DLN-191. etc. 18. CAUTION: A • Always be careful to work safely. • If items or work required are not covered by the engine section. • Always use the support point specified for lifting. If board-on type is used for unavoidable reasons. Refer to EM-140. Refer to M ST-19. 10. cap or plug openings to prevent fluid from spill- ing. "Garage Jack and Safety Stand". Remove front grille. F 2. 24. 3. "Removal and Installation". ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > [VQ40DE] • When lifting vehicle. Refer to EM-129. • For supporting points for lifting and jacking point at rear axle. E REMOVAL Preparation 1. 22. 11. tubes/lines. Refer to CO-40. 21. 15. "Removal and Installation". Release fuel pressure. "Removal and Installation". 25. L 17. D NOTE: When removing components such as hoses. Drain engine oil. Drain engine coolant. "Changing Engine Oil". Refer to EM-162. Refer to EC-968.

"Removal and Installation for VQ40DE 2WD Models" (2WD A/T models). Remove engine assembly from vehicle. CAUTION: • Before and during this lifting. If less than required quantity. Install engine slingers into left bank and right bank. • Run engine to check for unusual noise and vibration. • Summary of the inspection items: Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage Other oils and fluids* Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gas — Leakage — *Power steering fluid. "FOR USA AND CANADA : Fluids and Lubricants" (United States and Canada). Remove front frame crossmember. 28. Refer to TM-72. • Bleed air from passages in lines and hoses. 32. Remove transmission. • After cooling down engine. "Removal and Installation for VQ40DE 4WD Models" (4WD A/T models). • Warm up engine thoroughly to make sure there is no leakage of fuel. ENGINE ASSEMBLY < UNIT REMOVAL AND INSTALLATION > [VQ40DE] 26. check for fuel leak- age at connection points. 21 ft-lb) 27. Remove engine mounting insulator bracket (upper) with power tool. TM-308. such as in cooling system. check again for fuel leakage at connection points. check oil/fluid levels including engine coolant and engine oil. exhaust gas. again check oil/fluid levels including engine oil and engine coolant. 31. slack in the guide may generate a pounding noise during and just after engine start. Refill to spec- ified level. always check if any harnesses are left connected. or any oils/fluids including engine oil and engine coolant. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal and installation. avoiding interference with vehicle body. However. Engine slinger torque: 28. CAUTION: • When replacing an engine or transmission you must make sure the dowels are installed correctly during reassembly. TM-310.9 kg-m. • Improper alignment caused by missing dowels may cause vibration. brake fluid. With engine speed increased. etc. Refer to MA-19. • Use procedure below to check for fuel leakage. • Start engine. Lift with hoist and secure the engine in position. Noise will stop after hydraulic pressure rises. WBIA0624E 29. Remove engine mount bracket bolts. INSTALLATION Installation is in the reverse order of removal. Revision: August 2014 EM-218 2015 Frontier NAM . 30. oil leaks or breakage of driv- etrain components. this is normal. if necessary. fill to the specified level. • Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping.0 N·m (2. Refer to MA-16. "FOR MEXICO : Fluids and Lubricants" (Mexico). "Removal and Installa- tion from Vehicle (For 2WD Models)" (2WD M/T models) TM-74. "Removal and Installation from Vehicle (For 4WD Models)" (4WD M/T models). INSPECTION AFTER INSTALLATION • Before starting engine.

Water connector 7. Connecting rod bearing cap 18. Snap ring 21. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] UNIT DISASSEMBLY AND ASSEMBLY A ENGINE UNIT Exploded View INFOID:0000000010709751 EM C D E F G H I J K L M N WBIA0582E 1. Sub harness 5. Pilot converter (A/T models) 11. Reinforcement plate 2. Second ring 25. Flywheel 3. Main bearing 12. Connecting rod bearing 19. Piston 23. Crankshaft key 14. Drive plate (A/T models). Connecting rod 20. Piston pin 22. Thrust bearing 10. Oil jet 9. Connecting rod bolt 17. Lower cylinder block 15. Top ring Revision: August 2014 EM-219 2015 Frontier NAM . Crankshaft P 13. Lower cylinder block bolt 16. Oil ring 24. Cylinder block 8. Knock sensor 6. Rear oil seal (M/T models) O 4.

Remove clutch cover and clutch disc (M/T models). Remove both exhaust manifolds. "6M/T : Removal and Installation". 3. Gasket 3. Remove flywheel (M/T models) or drive plate (A/T models). "Removal and Installation". lock crankshaft to remove flywheel or drive plate bolts. Connector protector cap Disassembly and Assembly INFOID:0000000010709752 DISASSEMBLY NOTE: The following procedures explain how to disassemble the engine with the engine stand fastened to the bell housing. Refer to EM-148. • Place the drive plate with signal plate surface facing upward. KBIA2491E Revision: August 2014 EM-220 2015 Frontier NAM . a. Especially avoid deforming and damaging of signal plate teeth. • Loosen bolts diagonally. CAUTION: • Be careful not to damage or scratch drive plate (A/T models) or contact surface for clutch disc of flywheel (M/T models). 1. • Keep magnetic materials away from signal plate. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] PBIC2936E 1. 2. "Removal and Installation (Exhaust Manifold)". and separate the transmission assembly from the engine. Remove the engine and the transmission assembly from the vehicle. Refer to EM-216. Remove the parts that may restrict installation of engine to engine stand. b. Refer to CL-22. • Do not disassemble drive plate. Cylinder block 2. • Holding crankshaft pulley bolts. Cylinder block heater 4.

CAUTION: • Use an engine stand that has a load capacity [approxi- mately 240kg (529 lb) or more] large enough for support. F G H I J PBIC0805E K • 6. Drain engine oil. Lift engine. A Tool number : ST16610001 (J-23907) EM C WBIA0583E D 5. make sure the engine stand is stable and there is no risk of overturning. E ing the engine weight. Refer to LU-23. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] 4. Remove pilot converter (A/T models) using Tool as necessary. "Changing Engine Oil". L M N O P Revision: August 2014 EM-221 2015 Frontier NAM . and mount to engine stand. • Before removing the hanging chains.

PBIC2940E 14. Revision: August 2014 EM-222 2015 Frontier NAM . Refer to EM-230. do not shock or drop. CAUTION: Be careful not to drop connecting rod bearing or scratch the bearing surface. check the connecting rod side clearance. (B). and remove knock sensors. Remove piston and connecting rod assembly as follows: • Before removing piston and connecting rod assembly. 13. NOTE: For Canada. 9. Refer to EM-205. Refer to EM-230. 15. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] 7. 11. Push piston and connecting rod assembly out of the cylinder head side using suitable tool. CAUTION: Identify installation position. and store them without mixing them up. (C) and (D) from cylinder block as shown. check the piston ring side clearance. 12. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. Drain engine coolant by removing the cylinder block drain plugs (A). Remove piston rings from piston. CAUTION: Handle sensor carefully. "Inspection After Disassembly". WLIA0020E 8. 10. "Inspection After Disassembly". Remove connecting rod bearings from connecting rod and connecting rod bearing cap. • Before removing piston rings. Remove connecting rod bearing cap. Remove cylinder head. Remove sub harness. CAUTION: Be careful not to damage the cylinder wall or crankshaft pin resulting from an interference of the connecting rod big end. "Removal and Installation". (D) is not plug but block heater.

Heat piston to 60° to 70°C (140° to 158°F) with industrial use drier or equivalent. A CAUTION: • When removing piston rings. measure the crankshaft end play. E F G PBIC1638E H b. Remove piston from connecting rod as follows: a. "Inspec- tion After Disassembly". Remove snap ring using snap ring pliers. be careful not to damage piston. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] • Remove piston rings using piston ring expander or suitable tool. Push out piston pin with a drift which has an outer diameter of approximately 20 mm (0. EM • Be careful not to damage piston rings by expanding them excessively. Refer to EM-230.79 in). C PBIC0087E D 16. Remove lower cylinder block bolts. P Revision: August 2014 EM-223 2015 Frontier NAM . I J K PBIC1639E c. L M N PBIC0262E O 17. • Before loosening lower cylinder block bolts.

19. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] • Loosen lower cylinder block bolts in reverse order as shown in several different steps. or scratch the surface. Revision: August 2014 EM-224 2015 Frontier NAM . • Identify installation positions. Fully air-blow engine coolant and engine oil passages in cylinder block. Refer to EM-120. CAUTION: Be careful not to damage crankshaft or cylinder block. "Precaution for Liquid Gasket". NOTE: When replacing rear oil seal without removing lower cylinder block. use a suitable tool to pull the rear oil seal installed between crankshaft and cylinder block out. cylinder bore and crankcase to remove any foreign material. PBIC2941E 18. • Cut liquid gasket for removal. Tool number : KV10111100 (J-37228) CAUTION: Be careful not to damage the mounting surfaces. Pull rear oil seal out from rear end of crankshaft. Remove lower cylinder block. CAUTION: • Do not drop main bearing. NOTE: Use socket (size E14) for bolts No. 22. 1 to 16 (M10 bolt). ASSEMBLY 1. Remove main bearings and thrust bearings from cylinder block and lower cylinder block. Remove crankshaft. WARNING: Use goggles to protect your eyes. Remove oil jet. 20. and store them without mixing them up. 21.

EM Use Genuine High Strength Thread Locking Sealant or equivalent. H Block Plug and Block Heater Installation Part Washer Tightening Torque A No 19. "Disassembly and Assembly". (D) is not plug but block heater. Remove dust. Install main bearings and thrust bearings as follows: a.5 kg-m.0 N·m (2. Install each plug to cylinder block as shown. • Apply sealant to the thread of plug (C). "Recommended Chemical Products and Sealants". • Insert oil jet dowel pin into cylinder block dowel pin hole. Refer to GI-21. 46 ft-lb) D Yes Block heater 73. Install oil jet.8 N·m (1. 86 ft-lb) Plug 62 N·m (6. C Use Anaerobic Liquid Gasket or equivalent.0 kg-m. and engine oil on bearing mating surfaces of cylinder block and main bearing caps. 20 ft-lb) M N PBIC0898E O 4. 53 in-lb) J C Yes 116 N·m (11. Refer to GI-21. Refer to EM-220. dirt.3 kg-m. L Oil jet bolts : 27.0 kg-m. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] 2. 14 ft-lb) I Reuse 9.8 kg-m. A Use Genuine RTV Silicone Sealant or equivalent.61 kg-m.8 kg-m. • Replace washers with new washers. "Recommended Chemical Products and Sealants". • Apply sealant to the threads of plug (D). NOTE: D For Canada. E F G WLIA0020E • Tighten each plug as specified below. 87 in-lb) B No New 6. Refer to GI- 21.5 N·m (7. and tighten bolts to specifications. P Revision: August 2014 EM-225 2015 Frontier NAM .6 N·m (2. • Apply sealant to the thread of water drain plugs (A) and (B). "Recommended Chemical Products and Sealants".0 N·m (0. 54 ft-lb) K 3.

NOTE: There are more processes to complete the tightening bolts. • Ensure the oil holes on cylinder block and those on the corre- sponding bearing are aligned. Inspect the outer diameter of lower cylinder block bolt. a. the following pro- cedure must be performed quickly. Tighten lower cylinder block as follows: i.3 kg-m. d. 3 journal hous- ing on cylinder block. 7. Install crankshaft to cylinder block. • Install thrust bearings with the oil groove facing crankshaft arm (outside). 17 to 24. "Inspection After Disassembly". Bolts 17 . "Recommended Chemical Products and Sealants". Use Genuine RTV Silicone Sealant or equivalent. Apply a continuous bead of liquid gasket using a suitable tool to lower cylinder block as shown. Therefore. • Main bearing with oil hole and groove goes on cylinder block. • While turning crankshaft by hand. Install main bearings paying attention to the direction. because it is machined together with cylinder block. Apply new engine oil to threads and seat surfaces of the bolts. PBIC2941E c. • Install thrust bearing with a projection on one end on cylinder block. Do not apply engine oil to the back surface. • When installing. apply engine oil to the bearing surface (inside). 16 ft-lb) CAUTION: Wipe off completely any protruding liquid gasket on rear oil seal installation surface. However stop procedure here to install rear oil seal. Align projection with mating notch. PBIC2969E 5. Refer to GI-21. Refer to EM-203. Install thrust bearings to the both sides of the No. CAUTION: After liquid gasket is applied. The one without them goes on lower cylinder block. 6. Restart tightening of lower cylinder block bolts as follows: Revision: August 2014 EM-226 2015 Frontier NAM . b. align main bearing stopper protrusion to cut- out of cylinder block and lower cylinder block. Refer to EM-230. PBIC2968E c. Install rear oil seal. PBIC2942E ii. Install lower cylinder block as follows: NOTE: Lower cylinder block cannot be replaced as a single part. Tighten M8 bolts in numerical order as shown from No. check that it turns smoothly. • Before installing main bearings. "Removal and Installation of Rear Oil Seal". but thoroughly clean it.1 N·m (2.24 : 22. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] b. rear oil seal installation must be finished within 5 minutes.

Inspect the outer diameter of connecting rod bolt. L • Insert it fully into groove to install. • After installing. 60° to 70 °C (140° to 158 °F)]. "Inspection After Disassembly". Install piston to connecting rod as follows: a. Install piston rings using piston ring expander or suitable tool. J b. Install new snap ring to the groove of piston rear side using suitable tool. Turn M10 bolts 90° clockwise in numerical order from No.3 N·m (3. make sure that connecting rod moves smoothly. "Inspection After Disassembly". • Check the crankshaft end play. Do not make judgement by visual inspection. F G WBIA0584E • After installing the bolts. be careful not to damage piston. 1 to 16 using Tool. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] i. 1 to 16 (M10 bolt). H • Wipe off completely any protruding liquid gasket on front side of the engine. 1 to 16. Bolts 1 . Install piston to connecting rod. Tool number : KV10112100 (BT-8653-A) E CAUTION: Use angle wrench Tool to check tightening angle. From the front to the rear. Refer to EM-230. Tighten M10 bolts in numerical order as shown from No. NOTE: A Use socket (size E14) for bolts No. make sure that crankshaft can be rotated smoothly by hand. 26 ft-lb) EM C PBIC2941E D ii. insert piston pin into pis- ton and connecting rod. c. P • Be careful not to damage piston rings by expending them excessively. Install new snap ring to the groove of the piston front side. M N SEM838F 10. • Insert it fully into groove to install.16 : 35. 8. Refer to EM-230. I 9. • Using industrial use drier or similar tool. heat piston until piston pin can be pushed in by hand without excess force [approx.6 kg-m. K • Assemble so that the front mark on the piston head and the cylinder number on connecting rod are positioned as shown. PBIC0087E Revision: August 2014 EM-227 2015 Frontier NAM . O CAUTION: • When installing piston rings.

Stamped mark: Top ring :— Second ring : R SEM757G • Position each ring with the gap as shown referring to the pis- ton front mark. • When installing. no specific orientation is required for installation. align connecting rod bearing stopper protru- sion with cutout of connecting rods and connecting rod bearing caps to install. NOTE: If there is no stamp on ring. • Before installing connecting rod bearings. PBIC2067E 12. • Ensure the oil hole on connecting rod and that on the corre- sponding bearing are aligned. Tool number : EM03470000 (J-8037) CAUTION: Be careful not to damage the cylinder wall and crankshaft pin. resulting from an interference of the connecting rod big end. apply engine oil to the bearing surface (inside). NOTE: Be sure that front mark on piston head is facing front of engine. Do not apply engine oil to the back surface. 11. but thoroughly clean it. Install piston with the front mark on the piston head facing the front of engine using Tool. 16. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] • If there is stamped mark on ring. WBIA0585E Revision: August 2014 EM-228 2015 Frontier NAM . Install piston and connecting rod assembly to crankshaft. Refer to EM-230. PBIC0808E • Check the piston ring side clearance. Apply engine oil sufficiently to the cylinder bore. 15. piston and crankshaft pin journal. 14. 13. "Inspection After Disassembly". Match the cylinder position with the cylinder number on connecting rod to install. Install connecting rod bearings to connecting rod and connecting rod bearing cap. mount it with marked side up. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.

Apply engine oil to the threads and seats of connecting rod bolts. press-fit as far as it will go. replace it with new one. CAUTION: • Do not tighten bolts while holding connector. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] 17. Refer to EM-230. E b. Tighten connecting rod bolts. J • With drift of the following outer diameter. I "Inspection After Disassembly". Revision: August 2014 EM-229 2015 Frontier NAM . N O P SEM537E 20.0 kg-m. Connecting rod bolt : 19. WBIA0586E 19. 14 ft-lb) F c.30 in) L M PBIC2947E • Press-fit pilot converter with its chamfer facing crankshaft as shown. EM C PBIC0809E D 18. • If knock sensor is dropped. Install knock sensors. Then tighten all connecting rod bolts 90° clockwise. make sure that crank- shaft rotates smoothly. 33 mm (1.6 N·m (2. • Match the stamped cylinder number marks on connecting rod A with those on connecting rod bearing cap to install. Avoid tightening based on visual check G alone. Install pilot converter. Tool number : KV10112100 (BT-8653-A) H • After tightening connecting rod bolts. CAUTION: Always use Tool. Install connecting rod bearing cap. K Pilot converter : Approx. • Be sure that front mark on connecting rod bearing cap is fac- ing front of engine. • Check the connecting rod side clearance. Tighten connecting rod bolts as follows: a.

30 mm (0. Standard : 0. • Install knock sensor so that connector faces rear of engine. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] NOTE: • Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Tool number : — (J-48761) • Tighten bolts crosswise over several times.0. • Holding ring gear using Tool. • Make sure that knock sensor does not interfere with other parts. replace thrust bearings. PBIC0910E Inspection After Disassembly INFOID:0000000010709753 CRANKSHAFT END PLAY • Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with dial indicator.0039 .0. If it still exceeds the limit.10 . and lay it out to rear of engine.8 kg-m. replace crankshaft also. connect harness connector.25 mm (0. Knock sensor bolts : 18. 13 ft-lb) PBIC2948E 21. Assemble in the reverse order of disassembly after this step.1 N·m (1.0098 in) Limit : 0.0118 in) • If the measured value exceeds the limit. Drive plate (A/T models) • Install drive plate and reinforcement plate as shown. and measure again. • After installing knock sensor. PBIC2953E Revision: August 2014 EM-230 2015 Frontier NAM .

20 .006 mm (0. • Piston pin (piston pin hole) grade is provided only for the parts installed at the plant.005 mm (0.001 mm (0. NOTE: • Piston is available together with piston pin as assembly. PBIC2954E D PISTON TO PISTON PIN CLEARANCE Piston Pin Hole Diameter E Measure the inner diameter of piston pin hole with inside microme- ter. Replace piston and piston pin assembly. If it still exceeds the limit. replace crankshaft C also.40 mm (0.0.8657 .0.0.0079 .22.) PISTON RING SIDE CLEARANCE P Revision: August 2014 EM-231 2015 Frontier NAM .0.002 . N • When replacing piston and piston pin assembly. Standard : 0.0. no O piston pin grades can be selected.35 mm (0.0001 .22.0157 in) • If the measured value exceeds the limit. replace connecting rod. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] CONNECTING ROD SIDE CLEARANCE • Measure the side clearance between connecting rod and crank. "How to Select Piston and Bearing". F Standard : 21. and measure again.0138 in) EM Limit : 0.989 . A shaft arm with feeler gauge.993 .8663 in) G H PBIC0116E Piston Pin Outer Diameter Measure the outer diameter of piston pin with micrometer. I Standard : 21. (Only “0” grade is available. Refer to EM-243.8662 in) J K PBIC0117E L Piston to Piston Pin Oil Clearance (Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter) M Standard : 0.0.0002 in) • If the calculated value is out of the standard. For service parts.8659 .

0.0053 in) Limit: Top ring : 0.0028 in) Oil ring : 0. and measure the piston ring end gap with feeler gauge.85 mm (0. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] • Measure side clearance of piston ring and piston ring groove with feeler gauge. replace piston ring.68 mm (0.070 mm (0.0018 .0.0. Follow the "Cylinder Bore Inner Diameter" procedure.0.11 mm (0.0268 in) Oil ring : 0. Standard: Top ring : 0.0079 . CONNECTING ROD BEND AND TORSION Revision: August 2014 EM-232 2015 Frontier NAM .33 . Standard: Top ring : 0.0091 .10 mm (0.33 mm (0.0.0.0130 in) 2nd ring : 0. and then insert piston ring until middle of cylinder with piston.56 mm (0.080 mm (0.0197 in) PBIC0118E Limit: Top ring : 0. and measure again.045 .20 .23 .0.0039 in) • If the measured value exceeds the limit.0.0.0026 . replace piston also.0012 . PISTON RING END GAP • Make sure that the cylinder bore inner diameter is within the speci- fication.48 mm (0.135 mm (0. If it still exceeds the limit.030 .065 .0220 in) 2nd ring : 0. and measure again. • Lubricate with new engine oil to piston and piston ring.0043 in) SEM024AA 2nd ring : 0.0031 in) 2nd ring : 0.50 mm (0.0335 in) • If the measured value exceeds the limit. replace piston ring.0.0.0189 in) Oil ring : 0.0130 .0.

30 mm (0.22. replace connecting rod assembly.000 .2441 . ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] • Check with connecting rod aligner.15 mm (0. M Standard : 22. Refer to EM-220. A Bend: Limit: 0.0. C D E F G PBIC2077E CONNECTING ROD DIAMETER (BIG END) • Install connecting rod bearing cap without installing connecting rod H bearing.000 .8666 in) N O PBIC0120E Piston Pin Diameter P Revision: August 2014 EM-233 2015 Frontier NAM . PBIC1641E K CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END) Connecting Rod Bushing Inside Diameter (Small End) L Measure inside diameter of connecting rod bushing using suitable tool.012 mm (0. Standard : 57. I • Measure the inner diameter of connecting rod big end with inside micrometer.0059 in) per 100 mm (3.2446 in) J • If out of the standard.8661 .94 in) length Torsion: EM Limit: 0. replace connecting rod assembly. "Disassembly and Assembly" for the tightening procedure.0118 in) per 100 mm (3.2.57. and tightening connecting rod bolts to the specified torque.94 in) length • If it exceeds the limit.013 mm (2.

8657.0007 in) Limit : 0.017 mm (0. • If replacing piston and piston pin assembly.8661) (0.0. gasket.21.22.8664 .999 21. "How to Select Piston and Bearing".001 mm (0.22. sealant and carbon deposits from the cylinder block surface.989 .22.030 mm (0. replace connecting rod assembly and/or piston and piston pin assembly.999 .012 inner diameter * (0.0.006 .0012 in) • If the calculated value exceeds the limit.8666) 21.8659 . Unit: mm (in) Grade 0 1 Connecting rod bushing 22. 005 Piston pin hole diameter (0.0002 .0. scale.21.8657 .8662 in) PBIC0117E Connecting Rod Bushing Oil Clearance (Small End) (Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame- ter) Standard : 0. Revision: August 2014 EM-234 2015 Frontier NAM .001 Piston pin outer diameter (0.8663) 21.8659 .22.0. CAUTION: Do not allow any debris to enter engine oil or engine coolant passages. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] Measure diameter of piston pin using suitable tool.005 . Refer to EM-243. Standard : 21.8662) *: After installing in connecting rod PBIC2950E CYLINDER BLOCK DISTORTION • Remove any oil.0. follow the "CONNECTING ROD BEARING OIL CLEARANCE" procedure to select the con- necting rod bearing.8659) (0. • If replacing connecting rod assembly.0.000 .8661 .995 21. PBIC0809E Factory installed parts grading: • Only grade “0”.0.993 .995 .22.989 .006 22.0.8661 .0.8664) (0.

ENGINE UNIT
< UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE]
• Measure the distortion on the cylinder block upper face at some
different points in six directions with straightedge and feeler gauge. A

Limit : 0.1 mm (0.004 in)
• If it exceeds the limit, replace cylinder block. EM

C

SEM123C

D
MAIN BEARING HOUSING INNER DIAMETER
• Install lower cylinder block without installing main bearings, and
tighten lower cylinder block bolts to the specified torque. Refer to
EM-220, "Disassembly and Assembly" for the tightening proce- E
dure.
• Measure the inner diameter of main bearing housing with bore
gauge. F

Standard : 74.993 - 75.017 mm (2.9525 - 2.9534 in)
• If out of the standard, replace cylinder block and lower cylinder G
block as assembly.
NOTE: PBIC2012E

Cylinder block cannot be replaced as a single part, because it is H
machined together with lower cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter I
• Using bore gauge, measure cylinder bore for wear, out-of-round
and taper at six different points on each cylinder. [(X) and (Y) direc-
tions at (A), (B) and (C)] [(X) is in longitudinal direction of engine]. J

Standard inner diameter:
95.500 - 95.530 mm (3.7598 - 3.7610 in) K
Out-of-round [Difference between (X) and (Y)]:
0.015 mm (0.0006 in)
L
Taper limit [Difference between (A) and (C)]:
0.01 mm (0.0004 in) PBIC2955E

• If the measured value exceeds the limit, or if there are scratches M
and/or seizure on the cylinder inner wall, hone or re-bore the inner
wall.
N

O

SEM843E P
Piston Skirt Diameter

Revision: August 2014 EM-235 2015 Frontier NAM

ENGINE UNIT
< UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE]
Measure the outer diameter of piston skirt with micrometer.

Measure point
: Distance from the top 43.03 mm (1.6941 in)
Standard
: 95.480 - 95.510 mm (3.7590 - 3.7602 in)

PBIC2956E

Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter [direction (X), position (B)].
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter).

Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in)
• If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-243, "How to
Select Piston and Bearing".
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.

Re-bored size calculation: D = A + B – C
where,
D: Bored diameter
A: Piston skirt diameter as measured
B: Piston to cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
2. Install lower cylinder block, and tighten to the specified torque. Otherwise, cylinder bores may be distorted
in final assembly.
3. Cut cylinder bores.
NOTE:
• When any cylinder needs boring, all other cylinders must also be bored.
• Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.
4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure the finished cylinder bore for out-of-round and taper.
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with micrometer.

Standard : 69.951 - 69.975 mm (2.7540 - 2.7549 in) dia.
• If out of the standard, measure the main bearing oil clearance. Then use undersize bearing.
CRANKSHAFT PIN JOURNAL DIAMETER

Revision: August 2014 EM-236 2015 Frontier NAM

ENGINE UNIT
< UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE]
• Measure the outer diameter of crankshaft pin journal with
micrometer. A

Standard : 53.956 - 53.974 mm (2.1242 - 2.1250 in) dia.
• If out of the standard, measure the connecting rod bearing oil EM
clearance. Then use undersize bearing.

C

PBIC0127E

D
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
• Measure the dimensions at four different points as shown on each
main journal and pin journal with micrometer.
• Out-of-round is indicated by the difference in the dimensions E
between (X) and (Y) at (A) and (B).
• Taper is indicated by the difference in the dimensions between (A)
and (B) at (X) and (Y). F

Limit:
Out-of-round [Difference between (X) and (Y)] G
: 0.002 mm (0.0001 in)
SBIA0535E
Taper [Difference between (A) and (B)]
: 0.002 mm (0.0001 in) H

• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
the main bearing and/or connecting rod bearing. I

CRANKSHAFT RUNOUT
• Place V-block on precise flat table, and support the journals on the J
both end of crankshaft.
• Place dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on dial
indicator. (Total indicator reading) K

Standard : Less than 0.05 mm (0.002 in)
Limit : 0.10 mm (0.0039 in) L

• If it exceeds the limit, replace crankshaft.
SEM346D M
CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation
N
• Install connecting rod bearings to connecting rod and cap, and
tighten connecting rod bolts to the specified torque. Refer to EM-
220, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of connecting rod bearing with inside O
micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter) –
(Crankshaft pin journal diameter) P

Standard : 0.034 - 0.059 mm (0.0013 - 0.0023 in) (actu-
al clearance)
Limit : 0.070 mm (0.0028 in) PBIC1642E

• If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-243, "How to Select Piston and Bearing".
Revision: August 2014 EM-237 2015 Frontier NAM

ENGINE UNIT
< UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE]
Method of Using Plastigage
• Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
• Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-220, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
Do not rotate crankshaft.
• Remove connecting rod bearing cap and bearing, and using scale
on plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.

PBIC1149E

MAIN BEARING OIL CLEARANCE
Method by Calculation
• Install main bearings to cylinder block and lower cylinder block,
and tighten lower cylinder block bolts to the specified torque. Refer
to EM-220, "Disassembly and Assembly" for the tightening proce-
dure.
• Measure the inner diameter of main bearing with bore gauge.
(Bearing clearance) = (Main bearing inner diameter) – (Crankshaft
main journal diameter)

Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in)
(actual clearance)
Limit : 0.065 mm (0.0026 in) PBIC2204E

• If the calculated value exceeds the limit, select proper main bearing according to main bearing inner diame-
ter and crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-243, "How to
Select Piston and Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
• Cut plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to the
specified torque. Refer to EM-220, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
Do not rotate crankshaft.
• Remove lower cylinder block and bearings, and using scale on
plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.

PBIC1149E

CRUSH HEIGHT OF MAIN BEARING

Revision: August 2014 EM-238 2015 Frontier NAM

ENGINE UNIT
< UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE]
• When lower cylinder block is removed after being tightened to the
specified torque with main bearings installed, the tip end of bearing A
must protrude. Refer to EM-220, "Disassembly and Assembly" for
the tightening procedure.
EM
Standard : There must be crush height.
• If the standard is not met, replace main bearings.
C

SEM502G

D
CRUSH HEIGHT OF CONNECTING ROD BEARING
• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings installed, the
tip end of bearing must protrude. Refer to EM-220, "Disassembly E
and Assembly" for the tightening procedure.

Standard : There must be crush height. F
• If the standard is not met, replace connecting rod bearings.

G

PBIC1646E

LOWER CYLINDER BLOCK BOLT OUTER DIAMETER H
• Measure the outer diameters [(d1), (d2)] at two positions as shown.
• If reduction appears in (A) range, regard it as (d2).
I
Limit [(d1) - (d2)] : 0.11 mm (0.0051 in)
• If it exceeds the limit (large difference in dimensions), replace
lower cylinder block bolt with new one. J

K
PBIC0911E

CONNECTING ROD BOLT OUTER DIAMETER
• Measure the outer diameter (d) at position shown. L
• If the reduction appears in a position other than (d), regard it as (d).

Limit : 7.75 mm (0.3051 in) M
• When (d) exceeds the limit (when it becomes thinner), replace
connecting rod bolt with new one.
N

PBIC0912E
O

FLYWHEEL RUNOUT (M/T)
NOTE: P
• This inspection is for double mass flywheel only.
• Do not disassemble the double mass flywheel.
Flywheel Deflection

Revision: August 2014 EM-239 2015 Frontier NAM

ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] • Measure the deflection of the flywheel contact surface to the clutch with a dial gauge. and mark the movement amount on the mass on the transmis- sion side. Standard: 44.0177 in) or less • When measured value exceeds the limit. PBIC2168E MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS) CAUTION: Do not disassemble double mass flywheel. 87 in-lb) in each direction. replace the flywheel with a new one. • When handling signal plate.0 kg-m.3 mm (0. PBIC1263E • If measured value is out of the standard. clean or replace oil jet. Put a mating mark on circumferences of the two flywheel masses without applying any load (Measurement standard points). CAUTION: • Do not disassemble drive plate.8 N·m (1.45 mm (0. replace flywheel. and check for clogs. DRIVE PLATE (A/T MODELS) • Check drive plate and signal plate for deformation or cracks. and place a torque wrench on the extended line of the flywheel center line. 4.0 kg-m. 2.92 in) radius from the center of flywheel. • Measure the runout at 210 mm (8. • Do not place drive plate with signal plate facing down. OIL JET RELIEF VALVE Revision: August 2014 EM-240 2015 Frontier NAM . • If anything is found. 87 in-lb) to keep it from loosening.3 mm (1. • If it is not satisfied. Measure the dimensions of movement amounts (A) and (B) on circumference of flywheel on the transmission side.8 N·m (1. PBIC2938E OIL JET • Check nozzle for deformation and damage. • Tighten bolt at a force of 9. Limit : 0. • Blow compressed air from nozzle.2 kg. 3. Movement Amount of Thrust (Fore-and-Aft) Direction • Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.744 in) or less. 22 lb) force is added at the portion of 125 mm (4.27 in) diameter. take care not to damage or scratch it.051 in) or less • If measured value is out of the standard. replace drive plate. Install a bolt to clutch cover mounting hole. • Handle signal plate in a manner that prevents it from becom- ing magnetized. Movement Amount in Radial (Rotation) Direction Check the movement amount of radial (rotation) direction with the following procedure: 1. replace flywheel. Standard : 1. Apply a force of 9.

Use suitable tool to lock the drive plate (A/T models) or flywheel (M/T models) and match mark (A) the drive plate or flywheel before removing the bolts. EM C EMU0468D D Dowel Pin Alignment INFOID:0000000010709754 REMOVAL E 1. J • When handling the signal plate. N O ALBIA0522ZZ P Revision: August 2014 EM-241 2015 Frontier NAM . take care not to damage or scratch it. Remove drive plate (A/T models) or flywheel (M/T models). Installation is in the reverse order of removal. I • Loosen the drive plate or flywheel bolts in a diagonal order. CAUTION: • Do not place drive plate (A/T models) or flywheel (M/T models) with signal plate facing down. CAUTION: F Do not damage the ring gear teeth. use the M match mark (A) as shown to correctly align the crankshaft side dowel pin to the drive plate side dowel pin hole. replace oil jet relief valve. press check valve in oil jet relief valve. • Handle the signal plate in a manner that prevents it from K becoming magnetized SEM760G L INSTALLATION (A/T models) 1. Make sure that valve moves smoothly with proper reaction force. A • If it is not satisfied. or the signal plate teeth behind the ring gear. • When installing the drive plate to the crankshaft. G H ALBIA0522ZZ 2. ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] • Using clean plastic stick.

ENGINE UNIT < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] • Install the drive plate and the reinforcement plate in the direc- tion as shown. INSTALLATION (M/T models) 1. . Revision: August 2014 EM-242 2015 Frontier NAM . .Oil seal (4) AWBIA0539ZZ • There is a locator mark (B) on the clutch cover side of the fly- wheel (4).Flywheel (4) . Refer to this for ease of installation. Installation is in the reverse order of removal after the following. PBIC0910E • Tighten the drive plate bolts in a diagonal pattern in two steps. be sure to correctly align crankshaft side dowel pin (1) to the flywheel side dowel pin hole (A) as shown. • When installing the flywheel (3) to the crankshaft (2).Oil seal (2) . "Exploded View". • Be sure the dowel pin is installed in the crankshaft.Dowel pin hole (A) . "Disassembly and Assembly". Refer to EM-219.Dowel pin locator mark (B) AWBIA0540ZZ • Tighten the flywheel bolts in a diagonal pattern in two steps.Crankshaft (3) . Refer to EM-220.Crankshaft dowel pin (1) .

Refer to EM-230. • For details of the measurement method of each part. follow the applicable procedures. (Only L (0) grade piston pin is available. E Between crankshaft and con.) The information at the shipment from the plant is described as a reference. "Inspection After Disassembly". Determine the grade by comparing the I measurement with the values of each selection table.) M PBIC2949E N When Cylinder Block is Reused 1. J HOW TO SELECT PISTON When New Cylinder Block is Used Check the cylinder bore grade [(1). Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the “Piston Selection Table”. the grade for fitting cannot be selected between piston pin and connecting rod. C der block bearing housing Between cylinder block and Main bearing grade grade (inner diameter of hous- Main bearing crankshaft (bearing thickness) ing) and crankshaft journal grade (outer diameter of jour. • For reused or repaired parts. Connecting rod bearing grade Connecting rod bearing ter and crankshaft pin outer di- necting rod (bearing thickness) ameter determine connecting rod bearing selection. H • The identification grade stamped on each part is the grade for the dimension measured in new condition. F Piston and piston pin assembly Between cylinder block and pis.) Between piston and connecting G — — — rod* *: For the service parts. NOTE: Piston is available with piston pin as a set for the service part. Measure the cylinder bore inner diameter. HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] HOW TO SELECT PISTON AND BEARING A How to Select Piston and Bearing INFOID:0000000010709755 DESCRIPTION EM Selection points Selection parts Selection items Selection methods Determined by match of cylin. or (3)] on rear side of cylinder K block. the reuse standards and the selection method of the selective fitting parts. measure the dimension accurately. Piston grade Piston grade = cylinder bore (Piston is available together ton (piston skirt diameter) grade (inner diameter of bore) with piston pin as assembly. This grade cannot apply to reused parts. and select piston of the same grade. D nal) Combining service grades for connecting rod big end diame. P PBIC2950E Revision: August 2014 EM-243 2015 Frontier NAM . (Only (0) grade is available. O 2. (2).

1245 .7606 .506 .7602) (3.510 Piston skirt diameter (3.0.510 95.962 .500 .2.7602 .95.968 .013 (2.) • No second grade mark is available on piston.3. 4. HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] 3.530 Cylinder bore inner diameter (3.95.7610) 95. use undersize (US) bearings.53. and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. • When using undersize (US) bearing.0593 .503 (0. CAUTION: Revision: August 2014 EM-244 2015 Frontier NAM . 2. • Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. NOTE: There is no grading for connecting rod big end diameter.490 95. Select connecting rod bearing of the same grade. Piston Selection Table Unit: mm (in) Grade 1 2 (or no mark) 3 95. 5.509 (0.2.3. Measure the connecting rod big end diameter.490 . HOW TO SELECT CONNECTING ROD BEARING When New Connecting Rod and Crankshaft are Used Check pin journal grade [(0).500 .53.7602) NOTE: • Piston is available together with piston pin as assembly.1245) 2 1.510 .3.95.1. or (2)] on front of crankshaft. PBIC2951E When Crankshaft and Connecting Rod are Reused 1.7598 . 3.3.0592) STD 0 Black 53.7598 .0594) STD 2 Green Undersize Bearings Usage Guide • When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings. "Inspection After Disassembly".520 .95. (Only (0) grade is available.1.1247) 1 1. (1).0. Measure the crankshaft pin journal diameter.2.7594 . Color 53. no pis- ton pin grades can be selected.1.962 (2.1247 . Connecting Rod Bearing Selection Table Unit: mm (in) Connecting rod big end diameter 57.0591 .968 (2.2441 .3. "Inspection After Disassembly". Refer to EM-230.53.2446) Unit: mm (in) Crankshaft Connecting rod bearing Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No.7594) (3.503 .520 95.480 .1250) 0 1.506 (0.7598) (3.2.974 (2.000 .95.3.57.0.500 . Determine the grade of crankshaft pin journal grade by corresponding to the measured dimension in “Crankshaft pin journal diameter” column of “Connecting Rod Bearing Selection Table”.95. Select piston of the same grade.1242 .0593) STD 1 Brown 53. Make sure that the connecting rod big end diameter is within the standard value.7590 . For service parts. measure the connecting rod bearing inner diameter with bearing installed. Refer to EM-230.0592 .956 .7606) (3.500 95. and select connecting rod bearing of the same grade.

0640 .0098) 1.0.5 .1. “Main Bearing Selection Table” rows correspond to bearing housing grade on rear left side of cylinder block.7 mm (0. Correspond the measured dimension in “Crankshaft main journal diameter” column of “Main Bearing P Selection Table”. G H I PBIC2949E 2. “Main Bearing Selection Table” columns correspond to journal J diameter grade on front side of crankshaft. Select main bearing grade at the point where selected row and column meet in “Main Bearing Selection Table”. "Inspection After Disassembly".059 . 4. A EM C PBIC1908E Bearing undersize table D Unit: mm (in) Size Thickness E US 0.634 (0. 3. "Inspection After Disassembly" and EM-230. HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] In grinding crankshaft pin to use undersize bearings.067 in)].0643) HOW TO SELECT MAIN BEARING When New Cylinder Block and Crankshaft are Used F 1. N When Cylinder Block and Crankshaft are Reused 1.25 (0. Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of “Main Bearing Selection Table”. K L M PBIC2951E 3. keep the fillet R [1. O 2.626 .1. Select main bearing grade at the point where selected row and column meet in following selection table. Refer to EM-230. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Revision: August 2014 EM-245 2015 Frontier NAM .0.

HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] Main Bearing Selection Table WBIA0625E Main Bearing Grade Table (All Journals) Thickness Width Grade number Identification color Remarks Unit: mm (in) Unit: mm (in) Revision: August 2014 EM-246 2015 Frontier NAM .

512 (0.0993 .518 (0.2.059 .521 .503 (0.641 (0.0987) (0.0989 .512 . use under- side (US) bearing.518 .512 (0.2.509 (0.0993) Purple C 7 2.515 .2.0989) Yellow 23 LWR 2.0985) Black A 1 2.0991) Pink UPR 2.1 Green 12 LWR 2.0.512 .20. HOW TO SELECT PISTON AND BEARING < UNIT DISASSEMBLY AND ASSEMBLY > [VQ40DE] 0 2.0.0.0.1037 .0985 .0988) Green 3 2.0991 .0.509 (0.0989) Yellow Grade is the same for upper and lower bear- EM 4 2.0.0.0.0987) Brown 01 D LWR 2.506 .0.503 .0993) Purple I Undersize Bearing Usage Guide • When the specified main bearing oil clearance is not obtained with standard size main bearings.515 (0.0994) White UPR 2.0985) Black UPR 2.515 .7 mm (0.2.0.2.512 (0.0989 .0.503 .067 in)].2.515 (0.515 (0.506 (0.0.518 (0.0993) Purple 56 H LWR 2. CAUTION: K In grinding crankshaft main journal to use undersize bearings.515 .0990) Blue UPR 2.521 (0.2.521 .521 (0.0984 .25 (0.2. 5 2.0.500 .1040) P Revision: August 2014 EM-247 2015 Frontier NAM .509 .0987) Brown 2 2.0. and grind main journal so that the main bearing oil clearance satisfies the standard.2.0987 .2.2. J • When using undersize (US) bearing.0990 .0988) 19.0.0985 .1.500 .524 (0.0.0991) Pink 6 2.0.0.524 (0.2.2.2.9 . keep the fillet R [1.0991 .0.509 (0.0988 .2.791) Brown E UPR 2.0.2.0991) Pink G 45 LWR 2.0990) Blue Grade is different for 34 upper and lower bear- LWR 2. measure the main bearing inner diameter with bearing installed.0.521 (0.0991 .0985 .0989) Yellow ings.509 .0.0.518 (0.512 .0. L M N PBIC1908E Bearing undersize table Unit: mm (in) O Size Thickness US 0.0.503 (0.506 (0.0988 .2.0990 .0987 .2.783 .0988 .0994) White 67 LWR 2.2.633 .2.503 .5 .506 . UPR 2.2.0988) Green F UPR 2.0987 .506 (0.0990) Blue ings.506 .0990 .0098) 2.2.0989 .509 .2.518 .0984 .0993 .518 .

SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit INFOID:0000000010709756 GENERAL SPECIFICATIONS Cylinder arrangement V-6 3 3.5 × 92. INTAKE MANIFOLD AND EXHAUST MANIFOLD Revision: August 2014 EM-248 2015 Frontier NAM .0.7 Standard 1.0. 142) kPa (kg/cm2.0. psi)/300 rpm Differential limit between cylinders 98 (1.“OFF”) PBIC0187E Unit: degree a b c d e f 244 240 −4 64 6 58 DRIVE BELT Tension of drive belts Auto adjustment by auto-tensioner INTAKE MANIFOLD COLLECTOR.954 (241.76 × 3.622) Valve arrangement DOHC Firing order 1-2-3-4-5-6 Compression 2 Number of piston rings Oil 1 Number of main bearings 4 Compression ratio 9.0 (3.30) Displacement cm (cu in) Bore and stroke mm (in) 95. 185) Compression pressure Minimum 981 (10. 14) Cylinder number SEM713A Valve timing (Intake valve timing control .275 (13.

875 (1.045 . 1 0.0.0.15 (0.004) EM Exhaust manifold 0. 4 23.0034) Camshaft journal oil clearance 0.33.9238) — Camshaft end play 0. 2.500 .188 (0.1.935 .0236 . 1 27.27.500 .587) Valve Lifter Unit: mm (in) Items Standard Valve lifter outer diameter 33.987 (1.465 .0218) — Camshaft journal diameter No.1 mm (0.02 (0.0014 .23.0. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] Unit: mm (in) Items Limit A Intake manifold collector 0.0059) K L M N SEM671 *1: Total indicator reading O Valve Seal Unit: mm (in) Items Standard P Valve seal installed height (H) 14.0.1.0.0018 .1.0030) Camshaft journal length No.7900 .0211 .115 . E CAMSHAFT AND CAMSHAFT BEARING Unit: mm (in) Items Standard Limit F No. 2. 1 25.25.3 .1.7974) 45.000 .9230 .3381) Revision: August 2014 EM-249 2015 Frontier NAM . 3.3377 .0.004) Surface distortion Intake manifold 0. 2.7821) Camshaft cam height (A) Exhaust 45.45.035 .655 (1.14. 1 26.1 (0.0094) I Intake 45.05 (0.012) SPARK PLUG C Make NGK Standard type* DILFR5A-11 D Gap (nominal) 1.521 (0.1.0846) — G No.076 (0.977 .0244) — Camshaft bracket inner diameter No. 3. 4 23.465 (0.23.445 .15 (0.021 (1.9260) — H No.1 (0.0.955 (1.0.26.0045 .45.24 (0.9 (0.3 (0.563 .7821) 44.075 .265 (1. 3. 4 0.0.7746 .9252 .086 (0.043 in) *: Always check with the Parts Department for the latest parts information.548 (1.7667) J Camshaft runout [TIR*1] Less than 0.0059) No.002) Camshaft sprocket runout [TIR*2] — 0.265 (1.1.0827 .0074) 0.0008) 0.

28 (0.36 (0.0.039 (0.90 (0.3283) 836U N836 8.3244) 826U N826 8.0.1.416 (0.3236) 824U N824 8.04 (0.3165) 806U N806 8.3276) 834U N834 8.3252) 828U N828 8.3291) 838U — 8.94 (0.0.3392) Valve lifter clearance 0.26 .011 .20 (0.3126) 796U N796 7.16 (0.000 .24 (0.3228) 822U N822 8.37 (0.3157) 804U N804 8.432 (0.3205) 816U N816 8.3134) 798U N798 7.015) 0.08 (0.012 . SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] Valve lifter hole diameter 34.3189) 812U N812 8.016) Exhaust 0.92 (0.0.3102) 790U N790 7.3173) 808U N808 8.3197) 814U N814 8.3150) 802U N802 8.016 (1.3142) 800U N800 8.96 (0.3118) 794U N794 7.304 .013 .3220) 820U N820 8.013) 0.3268) 832U N832 8.3110) 792U N792 7.00 (0.3386 .18 (0.32 (0.26 (0.3299) Revision: August 2014 EM-250 2015 Frontier NAM .14 (0.10 (0.0.34 (0.017) *: Approximately 80°C (176°F) Available Valve Lifter Unit: mm (in) Identification (stamped) mark* Thickness Intake Exhaust 788U N788 7.0005 .22 (0.98 (0.0.34 (0.012 .0015) Valve Clearance Unit: mm (in) Items Cold Hot* (reference data) Intake 0.34.0.3260) 830U N830 8.3181) 810U N810 8.0.38 (0.3213) 818U N818 8.308 .0.12 (0.30 (0.88 (0.010 .06 (0.02 (0.29 .0.

CYLINDER HEAD F Unit: mm (in) Items Standard Limit G Head surface distortion Less than 0.972 .0012) 0. 1 camshaft journal bear.360 .5 (1.228 .240) Intake 96.31.3 (1.0781) — H ing length I J K PBIC0924E L Valve Dimensions Unit: mm (in) M N O P SEM188 Valve head diameter (D) Intake 37.1.03 (0.0 .1 (0.2 .40 (0.3307) EM C D E SEM758G *: Always check with the Parts Department for the latest parts information.4.980) — Cylinder head No.0772 .7976) Valve length (L) Exhaust 93. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] Identification (stamped) mark* Thickness A Intake Exhaust 840U — 8.99 (3.4567 .37.4685) Exhaust 31. 27.7004) Revision: August 2014 EM-251 2015 Frontier NAM .385 (1.46 (3.1.5 (4.004) Normal cylinder head height (H) 126.1.3 .27.126.

113 (1.0.1.1.175 .020 .0.2348 .113 (0.6.1.0.955 .496 .9.09 (0.223 .32.1.970 (0.32.0.0025) 0.4961 .0032 .5 (0.280 .10.0012 .059 (0.003) Valve guide clearance Exhaust 0.5196 .516 (1.0.08 (0.0044) Valve seat interference fit Exhaust 0.4006 .2715) 32.0.10.1.0.096 (0.4967) 38.020)] (Service) Intake 38.2369) Cylinder head valve guide hole diameter 9.45°45′ Exhaust Intake 1.3927 .0.1.008) oversize (Service) Valve guide Outer diameter 10.4029) Inner diameter (Finished size) 6.996 (0.38.0.796 (1.5.32.2350) Intake Valve seat angle (α) 45°15′ .234 (0.0.4025 .004) Projection length “L” 12.975 .8 (0.2362 .051) Valve Guide Unit: mm (in) SEM950E Items Standard 0.018 (0.0008 .200 . SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] Intake 5.2905 .2709 .064 .613 (1.097 .5157 .0.2912) Intake 0.2354) Valve stem diameter (d) Exhaust 5.1.3935) 10.000 .716 (1.38.016 (1.5202) Valve seat outer diameter (d) Exhaust 32.0.0011 .0.38.4014) Interference fit of valve guide 0.043) Valve margin (T) Exhaust 1.196 (0.2344 .0.030 .5005) 38.980 (0.3 (0.4999 .504) Valve Seat Unit: mm (in) PBIC2745E Items Standard Oversize [0.2683) 32.0021) 0.700 .500 .5164) Cylinder head seat recess diameter (D) Exhaust 32.027 .063 (0.0.965 .0.38.0.2874 .000 .5.6 .296 (1.12.1.597 .3946 .0025 .0023) Items Standard Limit Intake 0.2 (0.216 (1.0.053 (0.2880) Intake 38.0038) Revision: August 2014 EM-252 2015 Frontier NAM .034 (0.3950) 10.10.2677 .023 .1 (0.081 .780 .32.

0012) Surface flatness Limit 0.1.0 (0.90°15′ Intake 120° Angle (α3) D Exhaust 120° Intake 1.1 (1.1.6.05 (0.1 (0. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] Intake 35 (1.38) Diameter (d1)*1 A Exhaust 28.0.449) Diameter (d2)*2 Exhaust 30.3.2 .2.7 (1.063) E Intake 5.8 (1.20 (1.130) Intake 36.42) at 37.36.500 .1988 . 37 .3.9 .0.0709) Squareness mm (in) Limit 2.9 .7602 .0 (0.6.236) 5.213) EM Intake 60° Angle (α1) Exhaust 60° Intake 88°45′ .510 (3.0 .017 (2.193 .90°15′ C Angle (α2) Exhaust 88°45′ .0.7606 .95.8531) Installation 166 .07 (1.0 .9.1.9534) Grade No.5.530 (3.539) CYLINDER BLOCK Unit: mm (in) L M N O PBIC2955E P Standard Less than 0.95.3 .510 .083) J Spark Plug Tube Unit: mm (in) Items Standard K Spark plug tube press-fit height (H) 37.6 (0.8 (1.232 .95) at 27. 3 95.19.055) Contacting width (W)*3 Exhaust 1.993 .188 (16.7606) Grade No.1988) F Depth (H) 6.95.95 .484 .004) Main bearing housing inner diameter Standard 74.4 (0.2028) Height (h) Exhaust 5.039-0.9525 .520 (3.00 (1.421 (38.2.236) *1: Diameter made by intersection point of conic angles (α1) and (α2) *2: Diameter made by intersection point of conic angles (α2) and (α3) G *3 : Machining data Valve Spring H Free height mm (in) 47.3 .3.9 . lb) at height mm (in) Valve open 373 .75.0.03 (0.429 .39.047-0.0 (0.4567) I Pressure N (kg.236) 4.1.520 .15 (0.7602) Cylinder bore Inner diameter Standard* Grade No. 1 95.1.05 .5.30.7610) Revision: August 2014 EM-253 2015 Frontier NAM . 2 95.7598 . 84 .1 (0.232 .7 .1949 .42.

U 75.016 (2.3.75. B 74.005 (2. Y 75.002 (2.2.003 .03 (1.9528) Grade No.2.2.002 .996 (2.0006) Limit Taper [Difference between (A) and (C)] 0. 7 75.490 . E 74.9532) Grade No.75.9531) Grade No. F 74.012 (2. S 75.011 .000 .9532 . 4 75.74.0012) 0.7594 .9534) Difference in inner diameter between cylinders Standard Less than 0.9533) Grade No.9525 .010 .7590 .9527) Grade No.9528 .9526) Grade No. 1 21.500 (3.8659 . 2 95.0012) PISTON.75.9527 .014 (2.9525) Grade No. M 75.9528 .9525 .75.3. K 75.74.9529 .9534 .009 (2.0.9531 . 1 95. P 75.95.9533) Grade No.0.003 (2.75.998 (2. V 75. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] Out-of-round [Difference between (X) and (Y)] 0.9528 .75.0.000 (2.01 (0.9532 .7598 .9528) Grade No.75.015 .995 (2.8663) — Piston to cylinder bore clearance 0. R 75.001 .2. W 75.9526 .7594) — Grade No.08 (0.9529) Grade No.007 .006 (2.993 . Piston Ring Revision: August 2014 EM-254 2015 Frontier NAM .013 (2. J 75.013 .21.2.9530) Grade No.75.993 .74.030 (0.75.75.22.75.75.998 .74.005 (0.001 (2.004 .7602) — Items Standard Limit (a) dimension 43.75.75.95. N 75.74.9533 .2.004 (2.9531) Grade No.2.9529) Main bearing housing inner diameter (Without bearing) grades Grade No.008 .2.9527) Grade No.0031) *: Always check with the Parts Department for the latest parts information.2.015 (0.9529) Grade No.2.010 .75.014 .995 .9528) Grade No.2.011 (2.2.017 (2.480 .8661 .9530) Grade No.009 .0.9530 . T 75. G 74.9530 .994 .2.510 (3. A 74.2.999 (0.2.997 (2.8661) — Piston pin hole diameter Grade No.999 (2.994 (2. PISTON RING AND PISTON PIN Available Piston Unit: mm (in) SEM882E Items Grade* Standard — Piston skirt diameter (A) Grade No.999 .95.2.0004) Grade No.2.9530 . D 74.007 (2.9534) Grade No.9529 . X 75.74.75.2.9531 . 0 21.2.012 .490 (3.008 (2.996 .015 (2.7598) — Grade No.75.9526 .9533 .9531) Grade No. H 75.010 (2.9532) Grade No.016 .3.9533 .9529 .2.03 (0.9526) Grade No.006 .500 .2.9526 .005 .9533) Grade No. C 74.2.9527 .75.999 .2.6941) — Grade No. L 75. 3 95.0004 .9526) Grade No.2.997 .

0.0189) 0.0079 .000 .0130) 0.30 (0.0012 .0.0031) 0.5283 . 0 21.0.20 .005 .56 (0.8662) — Piston to piston pin oil clearance 0.0.33 . 1 21.35 (0.92 (6.48 (0.0079 .20 .0.94)] — 0.070 (0.0.0335) Piston Pin D Unit: mm (in) Items Grade* Standard Limit Grade No.080 (0.68 (0.002 .0039) EM Oil ring 0.21.013 (2.0053) — Top 0.2446) — Side clearance 0.0007) 0.23 .0.995 .6.006 (0.0.0.0138) 40 (0.50 (0.000 . SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] Unit: mm (in) Items Standard Limit A Top 0.0059) Torsion [per 100 (3.0.8659 . 1 22.0.001 (0.0091 .030 (0.2441 .22.135 (0. 0 22. CONNECTING ROD G Unit: mm (in) Items Grade1 Standard Limit H Center distance 165.0.0028) 0.006 .065 .10 (0.8657 .0118) I Grade No.0001 .82 .0026 .22.0.33 (0.0157) 1: Always check with the Parts Department for the latest parts information.995 (0.2.030 .0.0.0268) C Oil (rail ring) 0.5323) — Bend [per 100 (3.0.0.989 .0197) 0.0002) — Connecting rod bushing oil clearance 0.0.15 (0.8661 .94)] — 0.0002 .045 .012 (0. K 2 : After installing in connecting rod CRANKSHAFT L Unit: mm (in) M N O SEM645 SBIA0535E P Revision: August 2014 EM-255 2015 Frontier NAM .0220) End gap 2nd 0.8666) — J Connecting rod big end diameter (Without bearing) 57.0012) F *: Always check with the Parts Department for the latest parts information.8664) — Connecting rod bushing inner diameter2 Grade No.006 (0.0.8659) — E Piston pin outer diameter Grade No.8664 .57.165.0018 .017 (0.0130 .0.85 (0.22.0.0.11 (0.0043) Side clearance 2nd 0.

969 (2.970 . W 69.951 (2.7547) Grade No.7545 .69.7542) Grade No.2.7548) Grade No. 2 53.974 (2.69.7542 .69.7545) Main journal diameter.2.7544) Grade No.7543) Grade No.954 (2. M 69.7548 .973 .959 (2.7546) Grade No.966 .0039 .0.002) Crankshaft runout [TIR*] Limit 0.2.968 (2.960 .968 (2.2.968 .7546) Grade No.7542 .7544 .53.7547 .972 (2.975 .002 (0.967 .2.96 .7544 . Y 69.7549 . H 69.69.2.955 .2.952 (2.968 .25 (0.965 .2.69. S 69. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] Grade Dimension Grade No.7540) Grade No.7548 .7542 .69.2.967 (2.002 (0. C 69.962 (2.963 (2. 7 69.7541 . 4 69. D 69. L 69.972 .970 (2.953 .958 (2.7542) Grade No.69.30 (0. R 69.2.1247 .956 .7548 .7544) Grade No.05 (0.69.2. N 69.7543) Grade No.69. P 69.962 .7541 .7547) Grade No.2.957 . T 69.7545 .0001) Standard Less than 0.956 .0.0039) Standard 0.960 (2.1250) Pin journal diameter.7540 .959 . U 69.69.7544 . B 69.7542) Grade No. J 69.973 (2.2.969 .69.53.69.1242 .2.962 .954 .2.2.69.7546 .966 (2.1247) Grade No.46.958 .7541) Grade No. X 69.69.7541) Grade No.7545) Grade No.971 .69.69.7548) Grade No.8126) Taper [Difference between (A) and (B)] 0.69.953 (2.1245 .7540 .974 (2.952 . (Dm) grade Standard Grade No.8094 .53.7546 .7546) Grade No.2.69. G 69.965 (2. V 69. (Dp) grade Standard Grade No.2.7540) Grade No.7546 .04 (1.7544) Grade No.1.69.69.69.2.2.961 .963 . F 69.69.10 (0.2.961 (2.69.0098) Crankshaft end play Limit 0.956 (2.955 (2.964 .10 .2. 1 53.7543 .957 (2.2.1245) Center distance (r) 45.2.2.7540) Grade No.0001) Limit Out-of-round [Difference between (X) and (Y)] 0.971 (2.7548) Grade No.69.0118) * : Total indicator reading MAIN BEARING PBIC2969E Grade number* UPR/LWR Thickness mm (in) Width mm (in) Identification color Remarks Revision: August 2014 EM-256 2015 Frontier NAM . K 69.2. A 69.7543 .2. E 69.7547 .7549) Grade No.974 . 0 53.962 (2.964 (2.7549 .

0.2.0985 .1.0991) Pink 6 — 2.512 (0.0990) Blue UPR 2.515 (0.0988) 19.503 .0990) Blue bearings.0643) Grind so that bearing clearance is the specified value.0.0989) Yellow 23 LWR 2.0988 .0.0.1.0988 .521 (0.0.0.634 (0.512 (0.0993) Purple C 7 — 2.0.1040) Grind so that bearing clearance is the specified value.0.521 (0.506 (0.0991) Pink UPR 2.1.2.503 (0.0993) Purple I *: Always check with the Parts Department for the latest parts information.521 .0993 .515 .0.0990) Blue Grade is different for 34 upper and lower LWR 2.2.0985 .0098) 2.518 .2.521 (0.506 .518 (0.2.0.035 .1. UPR 2.524 (0.0989 .503 (0.515 (0.0987) (0.0.0.500 .0985 .0.2.512 .2.0.2.791) Brown E UPR 2.0993) Purple 56 H LWR 2.2.0991 .2.512 .2.2.500 .2.0098) 1. K Main Bearing Oil Clearance Unit: mm (in) L Items Standard Limit Main bearing oil clearance 0.0.0989 .515 .783 .045 (0.0.503 .2.0.0994) White UPR 2.500 .0640 .0987 .2.1037 . Undersize Unit: mm (in) J Items Thickness Main journal diameter 0.0987) Brown 01 D LWR 2.506 .0993 .0.0994) White 67 LWR 2.0.2.0.25 (0.503 .0988) Green F UPR 2.0991 .518 (0.2.0026) *: Actual clearance M CONNECTING ROD BEARING Grade number* Thickness mm (in) Identification color (mark) N 0 1.0593) Brown O 2 1.512 .0.521 .503 .0987 .25 (0.2.0987 .0990 .0.2. Connecting Rod Bearing Oil Clearance Revision: August 2014 EM-257 2015 Frontier NAM .633 .0591 .0.0.2.2.641 (0.0984 .0.0990 .20.9 . Undersize P Unit: mm (in) Items Thickness Crank pin journal diameter 0.518 .0989) Yellow Grade is the same for upper and lower EM 4 — 2.506 .506 (0.0988) Green 3 — 2.509 (0.509 .0987) Brown 2 — 2.509 (0. 5 — 2.506 .0014 .509 (0.512 (0.0594) Green *: Always check with the Parts Department for the latest parts information.0.0.2.0985) Black UPR 2.509 .506 (0.0989 .0.0988 .0593 .0.0989) Yellow bearings.0984 .509 .0592 .0018)* 0. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] 0 — 2.0990 .0985) Black A 1 — 2.515 .0.509 (0.0991 .506 (0.518 (0.626 .518 .0991) Pink G 45 LWR 2.065 (0.524 (0.0592) Black 1 1.503 (0.1 Green 12 LWR 2.2.515 (0.

0.059 (0.0023)* 0.0.0028) *: Actual clearance Revision: August 2014 EM-258 2015 Frontier NAM .034 .0013 .070 (0. SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) [VQ40DE] Unit: mm (in) Items Standard Limit Connecting rod bearing oil clearance 0.