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Nissan Frontier Navara Terrano Hardbody D22 1997-2004 factory workshop and repair manual download
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Nissan Frontier Navara Terrano Hardbody D22 ute/truck engine factory workshop and repair manual 1997-2004on PDF can be viewed using free PDF reader like adobe , or foxit or nitro . It is compressed as a zip file which you can extract with 7zip File size 122 Mb PDF document with bookmarks. Covers the Nissan Frontier Navara Terrano Hardbody D22 General Information covers the engines QD32 , KA24DE, VG30E, YD25DDTi, ZD30DDT, KA24E, VG33E, About the Nissan Navara D22
Nissan Navara is the name for the D22 and D40 generations of Nissan pickup trucks sold in Asia while in the North, Central and South America and the Philippines it's sold as Nissan Frontier. The line was started in 1998, and its immediate predecessor is the D21 Nissan Hardbody truck. As of 2002, the D22 series Nissan Truck is no longer sold in Japan, with the primary market having been relocated to North America. It is now built at the Smyrna, Tennessee Nissan factory.Nissan was the pioneer of the "Hardbody" or "Nissan Frontier" since 1986. The first was the D21, considered to be a small pick up. After more than 10 many years with the D21, the second generation Navara was manufactured from 1998 and went until 2005 which was classed as a compact sized pick up. It was changed with the bigger, taller, longer D40, which Nissan now considers to be a mid-size choose up truck.The Navara gets its name from the Navarre region of northern Spain, and the European variation is built at the Nissan factory in Barcelona.The Frontier was introduced in 1997 for the 1998 model year as a replacement for the aging 1986.5–1997 Nissan Hardbody Truck. Nissan first offered the Frontier with a 4-cylinder engine, the KA24DE, but added the V6 engine, the VG33E in 1999. Somewhere else, the Frontier was also known as the Nissan Navara.That changed, with the introduction of the 2000 Frontier Crew Cab. Chevrolet produced 4 door variations of its S-10 pickup in the late 90's, and Nissan began making its own 4 door version of the compact truck in 2000.For 2001, Nissan facelifted the Frontier, introducing bolder styling in an effort to make it more appealing to younger buyers in its second generation. The Frontier was completely redone after the 2004 model year, which later resulted in the suspension of the regular cab model, indefinitely. D22 (GEN-1) Names Datsun Japan, Frontier USA, Canada, Philippines, Argentina, Mexico and Brazil, Fiera Bolivia,Terrano Chile,Pick Up Europe, Central and South America, Africa, Asia ,Hardbody (codename J24) South Africa, Navara Europe and Australasia, Winner Middle East (Crew Cab only), Didsun or Datsun Persian Gulf countries, NP300 Frontier; Mexico in Mexico is a luxury trim of the NP300. Built in Japan from 1997 to 2000. Versions: solitary cab, King Cab, Crew Cab (Introduced in 2000 and only available on 2000-current models). Motors: Petrol (KA24DE) and Diesel (TD27) (4wd and 2wd) with 5 speed manual transmission. These models were additionally exported to Central and South America. US production in Tennessee started in 1998 with a solitary cab and a King cab. A Crew Cab arrived in 2000.In 2000, a special edition had been offered. Nissan called it the Desert Runner. It had a king cab base but on the 4X4 frame which gave it a boost in ride height, bigger tires and a 4-speed 2WD drivetrain. In 2001 the Desert Runner got a new look and a supercharged version of the V6 engine.Engines: 143 hp (107 kW) 2.4-liter (KA24DE) I4 and 170 hp (127 kW) 3.3-liter (VG33E) V6, Manual, 2wd or 4wd and Automatic. Japanese Production exported to South, Central America.The D22 Navara was a compact size pick up truck manufactured from 1997 to 2004. Nevertheless, Nissan goes on to build the D22 as a cheaper alternative to the current D40, and is understood as "Pickup". The first D22 Navaras (from 1997 to 2000) have actually a slightly different cosmetic appearance to the more recent designs (2001–2004). The first series of D22s had larger (QD32) 3.2-litre normally aspirated Diesel engines producing 75 kW. The second series has 4 available motor types. They were as follows:KA24DE: DOHC, 2.4-litre, 16V, 4-cylinder, producing 110 kW (148 hp) @ 5600 rpm and 208 NÃÂm (153 lbÃÂft) @ 3600 rpm. YD25DDTi (133 PS): 2.5-litre, DOHC, 16V, 4-cylinder, Turbo diesel intercooler, creating 98 kW (133 PS; 131 hp) @ 4000 rpm and 304 NÃÂm (31 kgÃÂm; 224 lbÃÂft) @ 2000 rpm. ZD30DDT: 3.0-litre, DOHC, 16V, Turbo, 4-cylinder diesel (non intercooler), producing 110 kW (148 hp) @ 3400 rpm and 314 NÃÂm (232 lbÃÂft) @ 2000 rpm. 6-cylinder, SOHC, 3.3-litre, 12V, producing 125 kW (168 hp) @ 4800 rpm and 266 NÃÂm (196 lbÃÂft) @ 2800 rpm. Currently the D22 Navara series remains on Nissan lineup for many nations and is known as Nissan NP300, Pickup, Frontier and Navara D22. In 2009 the D22 was updated with redesigned exterior door handles.The first Gen Frontier (2001–2004) was not sold in Japan. It was only produced in Japan for export. Product sales and production started in North America, with Crew Cab and King Cab versions and new bumper, taillights, headlights, grille. Other body changes included built in fender flares and tailgates. Available engines include a petrol 143 hp (107 kW) 2.4-liter Inline-4, 180 hp (134 kW) 3.3-liter V6, and a 210 hp (157 kW) 3.3-liter V6 Supercharged version. It's available with both 2-wheel and 4-wheel drive. Nissan began exporting the second generation to central and South America where it is called the Nissan Frontier. Solitary cabs and crew cabs are offered with the Diesel or Petrol engines, 2wd and 4wd. It's additionally available in New and Australia Zealand. The Brazilian plant began production around 2002 (Crew Cab Diesel 2wd or 4wd, 5-speed manual, or single cab 2wd Diesel. Just for Mexican market: petrol 2.4L manufactured in Mexico) and export to Argentina (all Brazilian versions) and Mexico (Crew Cab, Petrol 2.4L, 2wd, Manual 5-speed). The Egyptian Plant exports to the Middle East, and a South African Plant to African countries. Mexican production, starting in 2008: D22 truck Single Cab Chassis and Long Bed (4wd or 2wd, Petrol 2.4L or Diesel, Crew Cab (2wd and Petrol) called the D22 Pick up.Nissan Bolivia actually imports from Japan the Nissan Frontier D-22 Crew Cab, Petrol 2.4 or Diesel, 4x4. Imported from Mexico, the D-22 Crew Cab and single cab long Petrol, bed 4x2. Some Frontiers were imported from the USA. These were V6 and Automatic for private importers. Nissan Frontier Navara Terrano Hardbody D22 ute/truck engine factory workshop and repair manual 1997-2004 Download |
#### Tools Needed:
1. **Socket Set** (10mm and 12mm sockets)
2. **Ratchet and Extensions**
3. **Torque Wrench**
4. **Flathead Screwdriver**
5. **Wire Cutters/Crimpers** (if necessary)
6. **Multimeter** (for testing)
7. **Pliers**
8. **Clean Rags**
9. **Safety Glasses**
10. **Gloves**
#### Replacement Parts:
- **New Clutch Pressure Sensor** (ensure compatibility with D22 model)
- **New O-ring** (if applicable)
### Safety Precautions:
1. **Disconnect Battery:** Always disconnect the negative terminal of the battery before starting work to prevent electrical shorts or shocks.
2. **Work in a Ventilated Area:** Ensure the workspace is well-ventilated, especially if working indoors.
3. **Use Protective Gear:** Wear safety glasses and gloves to protect against debris and sharp edges.
4. **Secure Vehicle:** If working under the vehicle, use jack stands to secure it properly.
### Step-by-Step Replacement Process:
#### 1. **Preparation**
- Park the vehicle on a flat surface.
- Engage the parking brake.
#### 2. **Access the Clutch Pressure Sensor**
- **Locate the sensor:** The clutch pressure sensor is typically located near the clutch master cylinder, on the transmission housing.
- **Remove necessary components:** Depending on your vehicle configuration, you may need to remove the air intake duct or other components to gain access.
#### 3. **Disconnect the Electrical Connector**
- Carefully unclip and disconnect the electrical connector from the clutch pressure sensor. Use a flathead screwdriver if the clip is stubborn.
#### 4. **Remove the Old Sensor**
- Use a socket wrench to unscrew the old clutch pressure sensor (usually a 10mm or 12mm bolt). Turn counterclockwise until it is free.
- If there is an O-ring, note its position for the new sensor.
#### 5. **Install the New Sensor**
- Apply a small amount of engine oil or grease to the O-ring of the new sensor (if applicable) to ensure a good seal.
- Screw in the new sensor by hand to prevent cross-threading. Then, use a torque wrench to tighten it to the manufacturer's specifications (consult service manual for specific torque values).
#### 6. **Reconnect the Electrical Connector**
- Firmly reconnect the electrical connector to the new clutch pressure sensor until you hear a click, ensuring a solid connection.
#### 7. **Reassemble Removed Components**
- Reinstall any components that were removed to access the sensor, such as the air intake duct or any shields.
#### 8. **Reconnect the Battery**
- Reattach the negative battery terminal and ensure it is secure.
#### 9. **Test the Installation**
- Start the vehicle and check for any warning lights related to the clutch system.
- Use a multimeter to check the sensor's output if required (consult service manual for specifications).
- Take the vehicle for a short test drive to ensure everything is functioning correctly.
### Common Pitfalls to Avoid:
- **Cross-threading the Sensor:** Always hand-tighten before using a wrench.
- **Neglecting Electrical Connections:** Ensure connectors are fully seated to avoid intermittent issues.
- **Using Incorrect Torque Values:** Refer to the service manual for accurate torque specifications.
- **Overlooking O-ring Replacement:** A worn O-ring can lead to leaks, so replace it if necessary.
### Conclusion
Following these detailed steps ensures a successful clutch pressure sensor replacement on a Nissan Frontier Navara Terrano Hardbody D22. Always refer to the vehicle's service manual for specific details and torque specifications.
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