Nissan Frontier D40. Manual - part 603

EM-144

< ON-VEHICLE REPAIR >

[VQ40DE]

INTAKE MANIFOLD

• Check the surface distortion of the intake manifold mating surface

with straightedge and feeler gauge.

• If it exceeds the limit, replace intake manifold.

INSTALLATION

Installation is in the reverse order of removal. Note the following:

Intake Manifold

• If stud bolts were removed from cylinder head, install them and tighten to the specified torque.

• Tighten all nuts and bolts to the specified torque in two or more

steps in numerical order as shown.

Limit

: 0.1 mm (0.004 in)

PBIC0870E

Intake manifold studs

: 11.0 N·m (1.1kg-m, 8 ft-lb)

Intake manifold bolt and nuts

1st step

: 7.4 N·m (0.75 kg-m, 65 in-lb)

2nd step and after

: 29.0 N·m (3.0 kg-m, 21 ft-lb)

PBIC2879E

EXHAUST MANIFOLD AND THREE WAY CATALYST

EM-145

< ON-VEHICLE REPAIR >

[VQ40DE]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

EXHAUST MANIFOLD AND THREE WAY CATALYST

Exploded View

INFOID:0000000005274332

Removal and Installation (Three Way Catalyst)

INFOID:0000000005588755

WARNING:

Perform the work when the exhaust and cooling system have cooled sufficiently.

REMOVAL 

1.

Remove the front wheel and tire. Refer to 

WT-46, "Rotation"

.

2.

Remove the front fender protector. Refer to 

EXT-22, "Removal and Installation of Front Fender Protector"

.

3.

Remove the exhaust manifold cover bolts.

4.

Remove the center exhaust tube, main muffler and front exhaust tube. Refer to 

EX-5, "Exploded View"

.

5.

Disconnect the air fuel ratio sensor 1 harness connector.

6.

Remove the three way catalyst nuts and remove the three way catalyst.

7.

Remove the air fuel ratio sensor 1 using Tool, if necessary.

1.

Cylinder head (LH)

2.

Cylinder head (RH)

3.

Exhaust manifold studs (RH)

4.

Gasket

5.

Exhaust manifold nuts (RH)

6.

Exhaust manifold (RH)

7.

Exhaust manifold cover (RH)

8.

Three way catalyst (RH)

9.

Three way catalyst studs (RH)

10. Seal ring

11. Three way catalyst nuts (RH)

12.

Three way catalyst nuts (LH)

13. Seal ring

14. Three way catalyst studs (LH)

15.

Three way catalyst (LH)

16. Exhaust manifold cover (LH)

17. Exhaust manifold (LH)

18.

Exhaust manifold nuts (LH)

19. Gasket

20. Exhaust manifold studs (LH)

ALBIA0654GB

EM-146

< ON-VEHICLE REPAIR >

[VQ40DE]

EXHAUST MANIFOLD AND THREE WAY CATALYST

CAUTION:

• Be careful not to damage air fuel ratio sensor 1.
• Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0.5 m

(19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor. 

INSTALLATION

Installation is in the reverse order of removal.
• Tighten air fuel ratio sensor 1 to specification, if removed.

CAUTION:

• Do not over tighten air fuel ratio sensor 1. Doing so may cause damage to air fuel ratio sensor 1,

resulting in the “MIL” coming on.

• Before installing a new air fuel ratio sensor 1, clean exhaust system threads using oxygen sensor

thread cleaner and apply anti-seize lubricant.

Removal and Installation (Exhaust Manifold)

INFOID:0000000005274333

REMOVAL (LH)

WARNING:

Perform the work when the exhaust and cooling system have cooled sufficiently.

1.

Remove engine room cover. Refer to 

EM-138, "Removal and Installation"

.

2.

Remove air cleaner case (upper) and air duct and resonator assembly. Refer to 

EM-139, "Removal and

Installation"

.

3.

Remove engine under cover. Refer to 

EXT-13, "Removal and Installation"

.

4.

Partially drain engine coolant. Refer to 

CO-39, "Changing Engine Coolant"

.

5.

Remove three way catalyst (LH). Refer to 

EM-145, "Removal and Installation (Three Way Catalyst)"

.

6.

Remove exhaust manifold cover (LH).

7.

Remove oil level gauge and oil level gauge guide. Refer to 

EM-149, "Exploded View"

.

8.

Disconnect water hoses at heater pipe. Refer to 

CO-56, "Exploded View"

.

9.

Remove heater pipe from cylinder head (LH). Refer to 

CO-56, "Exploded View"

.

10. Loosen nuts in reverse order as shown.

•

: Front

NOTE:
Disregard the numerical order No. 7 and 8 in removal.

11. Remove exhaust manifold (LH).

12. Remove gaskets.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

INSPECTION AFTER REMOVAL

Surface Distortion

Tool number 

: KV991J0050 (J-44626)

Air fuel ratio sensor

: 50.0 N·m (5.1 kg-m, 37 ft-lb)

Oxygen sensor thread cleaner

: —   (J-43897-12) 

Oxygen sensor thread cleaner

: —   (J-43897 18)

AWBIA0725ZZ

EXHAUST MANIFOLD AND THREE WAY CATALYST

EM-147

< ON-VEHICLE REPAIR >

[VQ40DE]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

• Check the surface distortion of the exhaust manifold mating sur-

face with straightedge and feeler gauge.

• If it exceeds the limit, replace exhaust manifold.

INSTALLATION (LH)

Installation is in the reverse order of removal.

Exhaust Manifold Gasket

Install the exhaust manifold gasket in direction as shown.
•

: Front

• A: Identification hole

Exhaust Manifold

• If exhaust manifold studs were removed, install them and tighten to specification.
• Install exhaust manifold and tighten nuts in numerical order as

shown.

CAUTION:

Use new exhaust manifold nuts for installation.
NOTE:
Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7
and 8 show second step.

-

: Front

REMOVAL (RH)

1.

Remove three way catalyst (RH). Refer to 

EM-145, "Removal and Installation (Three Way Catalyst)"

.

2.

Remove heat shield from lower dash panel.

3.

Remove support bolts from A/T fluid charging pipe (A/T models). Refer to 

TM-297, "Component"

.

4.

Loosen nuts in reverse order as shown.
•

: Front

NOTE:
Disregard the numerical order No. 7 and 8 in removal.

5.

Remove exhaust manifold (RH) and exhaust manifold cover (RH) together.

6.

Remove gaskets.

Limit

: 0.3 mm (0.012 in)

PBIC1096E

AWBIA0726ZZ

AWBIA0725ZZ

AWBIA0727ZZ