2002 NISSAN FRONTIER engine service

Welcome To The World Of NISSAN
Your new NISSAN is the result of our dedication
to produce the finest in safe, reliable and eco-
nomical transportation. Your vehicle is the prod-
uct of a successful worldwide company that
manufactures cars and trucks in over 17 coun-
tries and distributes them in 170 nations.
NISSAN vehicles are designed and manufac-
tured by Nissan Motor Co., Ltd. which was
founded in Tokyo, Japan in 1933, and NISSAN
affiliates world wide, collectively growing to be-
come the fifth largest automaker in the world. In
addition to cars and trucks, NISSAN also makes
forklift trucks, marine engines, boats and other
diversified products.
NISSAN has made a substantial and growing
investment in North America. NISSAN's commit-
ment is nearly $4 billion dollars in capital invest-
ments in facilities across the continent. Some ofthe facilities include the Nissan Manufacturing
facility in Smyrna, Tennessee, vehicle styling
design at Nissan Design America, Inc. in San
Diego, California, and engineering at Nissan
Technical Center North America in Farmington
Hills, Michigan. Additionally, NISSAN employs
nearly 18,000 people throughout the United
States, Canada, and Mexico. An additional
71,000 people work for the 1,500 NISSAN and
INFINITI dealers across North America.
NISSAN is also a substantial contributor to the
Canadian economy. Nissan Canada Inc., its sup-
pliers and over 140 dealers employ approxi-
mately 4,500 people. These include company
employees and the staffs of NISSAN dealers all
across Canada. In addition, many Canadians
work for companies that supply NISSAN and
NISSAN dealers with materials and services
ranging from operation of port facilities and trans-portation services to the supply of lubricants,
parts and accessories.
NISSAN pioneered the use of electronics and
computers in automobiles, and has led the indus-
try in improving both performance and fuel effi-
ciency through new engine designs and the use
of synthetic materials to reduce vehicle weight.
The company has also developed ways to build
quality into its vehicles at each stage of the
production process, both through extensive use
of automation and Ð most importantly Ð
through an awareness thatpeopleare the cen-
tral element in quality control.
From the time the parts arrived from our suppli-
ers until you took delivery of your new NISSAN,
dozens of checks were made to ensure that only
the best job was being done in producing and
delivering your vehicle. NISSAN also takes great
care to ensure that when you take your NISSAN
to your dealer for maintenance, the service tech-
nician will perform his work according to the
quality standards that have been established by
the factory.
Safety has also been built into your NISSAN. As
you know, seat belts are an integral part of the
safety systems that will help protect you and your
passengers in the event of a sudden stop or an
accident. We urge you to use the seat belts every
time you drive the vehicle.
The NISSAN story of growth and achievement
reflects our major goal: to provide you, our
customer, with a vehicle that is built with quality
and craftsmanship Ð a product that we can be
proud to build and you can be proud to own.
WFW0002
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in the ``Maintenance and do-it-yourself''
section of this manual.
2. If the brake fluid level is correct, have the
warning system checked by an autho-
rized NISSAN dealer.
WARNING
c
Your brake system may not be work-
ing properly if the warning light is on.
Driving could be dangerous. If you
judge it to be safe, drive carefully to
the nearest service station for repairs.
Otherwise have your vehicle towed
because driving it could be danger-
ous.
cPressing the brake pedal with the
engine stopped and/or low brake
fluid level may increase your stop-
ping distance and require greater
pedal effort as well as pedal travel.
cIf the brake fluid level is below the
MINIMUM or MIN mark on the brake
fluid reservoir, do not drive until the
brake system has been checked at
an authorized NISSAN dealer.
Charge warning light
If this light comes on while the engine is
running, it may indicate the charging system
is not functioning properly. Turn the engine
off and check the generator belt. If the belt is
loose, broken, missing or if the light remains
on, see an authorized NISSAN dealer im-
mediately.
CAUTION
Do not continue driving if the belt is
loose, broken or missing.
Door open warning light (if
so equipped)
This light comes on when any of the doors
are not closed securely while the ignition
key is in the ON position.
Engine oil pressure warning
light
This light warns of low engine oil pressure. If
the light flickers or comes on during normal
driving, pull off the road in a safe area, stop
the engineimmediatelyand call an autho-
rized NISSAN dealer.The engine oil pressure warning light is
not designed to indicate a low oil level.
Use the dipstick to check the oil level.
See ``Engine oil'' in the ``Do-it-yourself'' sec-
tion of this manual.
CAUTION
Running the engine with the engine oil
pressure warning light on could cause
serious damage to the engine almost
immediately. Such damage is not cov-
ered by warranty. Turn off the engine
as soon as it is safe to do so.
Low fuel warning light
This light comes on when the fuel in the tank
is low. Refuel as soon as it is convenient,
preferably before the fuel gauge reaches E
(Empty).
There will be a small reserve of fuel
remaining in the tank when the fuel
gauge needle reaches E (Empty).
Low washer fluid warning
light
This light comes on when the washer tank
fluid is at a low level. Add washer fluid as
2-12Instruments and controls
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WARNING
cDo not leave children, unreliable
adults, or pets alone in your vehicle.
They could accidentally injure them-
selves or others through inadvertent
operation of the vehicle. Also, on
hot, sunny days, temperatures in a
closed vehicle could quickly become
high enough to cause severe or pos-
sibly fatal injuries to people or ani-
mals.
cProperly secure all cargo to help
prevent it from sliding or shifting. Do
not place cargo higher than the seat-
backs. In a sudden stop or collision,
unsecured cargo could cause per-
sonal injury.
EXHAUST GAS (carbon monoxide)
WARNING
cDo not breathe exhaust gases; they
contain colorless and odorless car-
bon monoxide. Carbon monoxide is
dangerous. It can cause uncon-
sciousness or death.cIf you suspect that exhaust fumes
are entering the vehicle, drive with
all windows fully open, and have the
vehicle inspected immediately.
cDo not run the engine in closed
spaces such as a garage.
cDo not park the vehicle with the
engine running for any extended
length of time.
c
If a special body, camper, or other
equipment is added for recreational
or other usage, follow the manufac-
turer's recommendation to prevent
carbon monoxide entry into the ve-
hicle. Do not occupy these areas
while the engine is running even if the
vehicle is parked. Some recreational
vehicle appliances such as stoves,
refrigerators, heaters, etc. may also
generate carbon monoxide.
cThe exhaust system and body
should be inspected by a qualified
mechanic whenever:
a. The vehicle is raised for service.
b. You suspect that exhaust fumes
are entering into the passengercompartment.
c. You notice a change in the sound
of the exhaust system.
d.
You have had an accident involv-
ing damage to the exhaust system,
underbody, or rear of the vehicle.
THREE-WAY CATALYST
The three-way catalyst is an emission control
device installed in the exhaust system. Ex-
haust gases in the converter are burned at
high temperatures to help reduce pollutants.
WARNING
cThe exhaust gas and the exhaust
system are very hot. Keep people,
animals or flammable materials
away from the exhaust system com-
ponents.
cDo not stop or park the vehicle over
flammable materials such as dry
grass, waste paper or rags. They
may ignite and cause a fire.
PRECAUTIONS WHEN
STARTING AND DRIVING
5-2Starting and driving
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Shifting (KA24DE engine)
Pull the selector lever rearward to shift into
P (Park), or R (Reverse) or from D (Drive) to
2or1.
WARNING
Apply the parking brake if the selector
lever is in any position while the engine
is not running. Failure to do so could
cause the vehicle to move unexpect-
edly or roll away and result in serious
personal injury or property damage.P (Park)
Use this position when the vehicle is parked or
when starting the engine. Always be sure the
vehicle is at a complete stop. For maximum
safety, depress the brake pedal, then move
the selector lever to the P (Park) position.
Apply the parking brake. When parking on a
hill, apply the parking brake first, then shift the
selector lever into the P (Park) position.
Shifting from P (Park)
If the ignition switch is in the ON position
and the foot brake pedal is depressed, but
the selector lever still cannot be moved out
of P (Park), use the following procedure:
1. Shut the engine off and remove the key.
2. Apply the parking brake.
3. Reinsert the key and turn it clockwise to
the ACC position.
4. Depress the brake pedal, move the se-
lector lever to N (Neutral).
5. Start the engine.
These instructions for starting the vehicle in
N (Neutral) should only be used until service
can be obtained at an authorized NISSAN
dealership.R (Reverse)
Use this position to back up. Shift into this
position only after the vehicle has com-
pletely stopped.
N (Neutral)
Neither forward or reverse gear is engaged.
The engine can be started in this position.
You may shift to N (Neutral) and restart a
stalled engine while the vehicle is moving.
D (Drive)
Use this position for normal forward driving.
2 (Second gear)
Use for moderate uphill grades, engine
braking on downhill grades or starting on
slippery surfaces.
Do not downshift into the 2 position at speeds
above 62 MPH (100 km/h), and do not exceed
62 MPH (100 km/h) in the 2 position.
1 (Low gear)
Use this position for steep uphill grades,
driving slowly through deep snow, sand or
mud, or for maximum engine braking on
steep downhill grades.
Do not downshift into the 1 position at
speeds above 30 MPH (48 km/h), and do not
exceed 30 MPH (48 km/h) in the 1 position.
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5-10Starting and driving
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Shifting (VG33E or VG33ER en-
gines)
Push the button to shift into P (Park), R
(Reverse) or from D (Drive) to 2. All other
positions can be selected without pushing
the button.
P (Park)
Use this selector position when the vehicle
is parked or when starting the engine. Al-
ways be sure the vehicle is at a complete
stop. For maximum safety, depress the
brake pedal, then push in the selector lever
button and move the lever to the P (Park)position. Apply the parking brake. When
parking on a hill, apply the parking brake
first, then shift the lever into the P (Park)
position.
Shifting from P (Park)
If the ignition switch is in the ON position
and the foot brake pedal is depressed, but
the selector lever still cannot be moved out
of P (Park), follow these instructions.
1. Turn the ignition key to the LOCK posi-
tion.
2. Apply the parking brake.3. Reinsert the key and turn it to the ACC
position.
4. Depress the foot brake pedal and move
the selector lever to N (Neutral).
5. Start the engine.
These instructions for starting the vehicle in
N (Neutral) should only be used until service
can be obtained at an authorized NISSAN
dealership.
R (Reverse)
Use this position to back up. Always be sure
the vehicle is at a complete stop before
shifting into the R (Reverse) position. For
maximum safety, check to ensure the area
behind the vehicle is clear. With the brake
pedal depressed, push in the selector lever
button and move the selector lever to the R
(Reverse) position.
N (Neutral)
Neither forward nor reverse gear is en-
gaged. The engine can be started in this
position. You may shift to N (Neutral) and
restart a stalled engine while the vehicle is
moving.
ASD1024
Starting and driving5-11
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Your new NISSAN has been designed to
have minimum maintenance requirements
with longer service intervals to save you
both time and money. However, some day-
to-day and regular maintenance is essential
to maintain your NISSAN's good mechani-
cal condition, as well as its emission and
engine performance.
It is the owner's responsibility to make sure
that the scheduled maintenance, as well as
general maintenance, is performed.
As the vehicle owner, you are the only one
who can ensure that your vehicle receives
proper maintenance. You are a vital link in
the maintenance chain.
Scheduled maintenance
For your convenience, both required and
optional scheduled maintenance items are
described and listed in your ``Nissan Service
and Maintenance Guide.'' You must refer to
that guide to ensure that necessary mainte-
nance is performed on your Nissan at regu-
lar intervals.
General maintenance
General maintenance includes those items
which should be checked during normalday-to-day operation of the vehicle. They
are essential if your vehicle is to continue to
operate properly. It is your responsibility to
perform these maintenance procedures
regularly as prescribed.
Performing general maintenance checks re-
quires minimal mechanical skill and only a
few general automotive tools.
These checks or inspections can be done
by yourself, a qualified technician or, if you
prefer, an authorized NISSAN dealer.
Where to go for service
If maintenance service is required or your
vehicle appears to malfunction, have the
systems checked and tuned by an autho-
rized NISSAN dealer.
NISSAN technicians are well-trained spe-
cialists who and are kept up-to-date with the
latest service information through technical
bulletins, service tips, and in-dealership
training programs. They are completely
qualified to work on NISSAN vehicles
beforethey work on your vehicle, rather
than after they have worked on it.
You can be confident that an authorized
NISSAN dealer's service department per-forms the best job to meet the maintenance
requirements on your vehicle Ð in a reliable
and economic way.
MAINTENANCE
REQUIREMENTS
8-2Maintenance and do-it-yourself
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cIf you must work with the engine run-
ning, keep your hands, clothing, hair
and tools away from moving fans,
belts, and any other moving parts.
cIt is advisable to secure or remove
any loose clothing and remove any
jewelry, such as rings, watches, etc.,
before working on your vehicle.
cAlways wear eye protection when-
ever you work on your vehicle.
cIf you must run the engine in an
enclosed space such as a garage, be
sure there is proper ventilation for
exhaust gases to escape.
cNever get under the vehicle while it
is supported only by a jack. If it is
necessary to work under the vehicle,
support it with safety stands.
c
Keep smoking materials, flame and
sparks away from fuel tank and battery.
cOn gasoline engine models with the
multiport fuel injection (MFI) system,
the fuel filter or fuel lines should be
serviced by an authorized NISSAN
dealer because the fuellines are un-der high pressure even when the
engine is off.
CAUTION
cDo not work under the hood while
the engine is hot. Turn the engine off
and wait until it cools down.
cNever connect or disconnect either
the battery or any transistorized
component connector while the igni-
tion is on.
cNever leave the engine or automatic
transmission related component
harnesses disconnected while the
ignition switch is in the ON position.
cAvoid contact with used engine oil
and coolant. Improperly disposed
engine oil, engine coolant and/or
other vehicle fluids can damage the
environment. Always conform to lo-
cal regulations for disposal of ve-
hicle fluid.
This ``Maintenance and do-it-yourself'' sec-
tion gives instructions regarding only those
items which are relatively easy for an owner
to perform.A genuine NISSAN service manual is also
available. See `Owner's Manual/Service
Manual order information'' in the ``Technical
and consumer information'' section.
You should be aware that incomplete or
improper servicing may result in operating
difficulties or excessive emissions, and
could affect your warranty coverage.If in
doubt about any servicing, have it done
by an authorized NISSAN dealer.
8-6Maintenance and do-it-yourself
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If the cooling system frequently requires
coolant, have it checked by an autho-
rized NISSAN dealer.
CHANGING ENGINE COOLANT
An authorized NISSAN dealer can change
the engine coolant. The service procedure
can be found in the NISSAN Service
Manual.
Improper servicing can result in reduced
heater performance and engine over-
heating.
WARNING
cTo avoid the danger of being
scalded, never change the coolant
when the engine is hot.
cNever remove the radiator cap when
the engine is hot. Serious burns
could be caused by high pressure
fluid escaping from the radiator.
cAvoid direct skin contact with used
coolant. If skin contact is made,
wash thoroughly with soap or hand
cleaner as soon as possible.
cKeep coolant out of reach of children
and pets.Engine coolant must be disposed of prop-
erly. Check your local regulations.
CHECKING ENGINE OIL LEVEL
1. Park the vehicle on a level surface and
apply the parking brake.
2. Start the engine and let it idle until it
reaches operating temperature.
3. Turn off the engine.Wait a few minutes
for the oil to drain back into the oil
pan.
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ENGINE OIL
Maintenance and do-it-yourself8-11
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