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Nissan Frontier Navara Terrano Hardbody D22 1997-2004 factory workshop and repair manual download

Below is a clear, practical guide to replacing the accessory (drive) belt on a Nissan D22 (Frontier / Navara / Terrano / Hardbody). I cover what every component is and does, why belts fail, what can go wrong, and a step‑by‑step procedure written for a beginner mechanic. I include safety and inspection points. I assume you mean the accessory/serpentine/drive belt (the belt that runs the alternator, A/C compressor, power steering pump, etc.). If you actually need the timing belt, that is a different, more complex procedure — do not proceed without a specific timing‑belt guide for your engine.

Quick overview / analogy
- The drive belt is like the rubber link between the engine’s “pedal” (crankshaft) and the accessories’ “wheels” (alternator, A/C, power steering). It transmits rotational power by friction. A proper belt must sit in the pulley grooves and have correct tension — too loose and it slips, too tight and bearings are overloaded.

Components — what they are and what they do
- Crankshaft pulley (harmonic balancer): the main drive pulley at the bottom of the engine. It provides the power to the belt. Don’t remove it for a belt change.
- Alternator pulley: driven by the belt to generate electrical power and recharge the battery.
- A/C compressor pulley: runs the air conditioning compressor when the A/C clutch engages.
- Power steering pump pulley: powers hydraulic power steering.
- Idler pulley(s): smooth, fixed pulleys that route the belt or change its path. They are basically bearings in a pulley wheel.
- Belt tensioner (automatic or manual): keeps belt tensioned. An automatic tensioner is spring‑loaded and maintains tension automatically; a manual tensioner is adjusted by loosening and moving a bolt to set tension.
- Belt (serpentine/drive belt): rubber reinforced with cords that wraps the pulleys.
- Engine bracketry/mounts: structural parts that hold accessories in place and that you might need to access.

Tools and supplies
- New drive belt (correct part number for your engine/model).
- Socket set and ratchet (metric; common sizes: 10, 12, 14 mm). Long-handled breaker bar or 1/2" ratchet for tensioner.
- Wrench set (metric).
- Torque wrench (to torque bolts back to spec).
- Pry bar or long-arm ratchet for tensioner if needed.
- Flashlight.
- Gloves and eye protection.
- Jack and jack stands (if needed for access from below).
- Pen and paper or phone to photograph/record belt routing.
- Optional: belt tension gauge (for manual tensioners).
- Optional replacement parts: idler pulley(s), belt tensioner (recommended if >80k km or noisy), accessory or mounting bolts if corroded.
- Clean rag and mild degreaser (for removing oil on pulleys).

Safety first
- Park on level ground, set parking brake, chock rear wheels.
- Engine off, keys out of ignition. Allow engine to cool.
- If you need to get under the vehicle, jack and support with jack stands; do not rely on the jack alone.
- Keep clothing/jewelry away from rotating parts; do not start engine with tools in place.
- Disconnect the battery negative if you will be working on electrical connectors or want additional safety.

How the system works (brief theory)
- The crankshaft pulley turns with the engine. The belt wraps around accessory pulleys; friction between the belt ribs and pulley grooves transfers torque to those accessories. The tensioner keeps the belt tight so it doesn’t slip. If the belt slips, accessories lose power (no charging from alternator, weak/absent power steering, no A/C). A belt also damps small vibrations.
- Automatic tensioners use a spring + damper to apply constant tension. Manual tensioners are adjusted to a target deflection or tightness.
- Belt wear mechanisms: age and heat dry the rubber and cause cracks; oil contamination causes the rubber to soften; misaligned pulleys cause uneven wear and noise; a failing bearing in an idler or accessory will seize or wobble and destroy the belt.

Signs you need a belt replacement
- Squealing or chirping on start or under load.
- Visible cracks, fraying, missing ribs, glazing (shiny surface) or chunks missing from the belt.
- Belt has excessive slack or is slipping.
- Accessory failure: battery not charging, A/C not working, hard steering (if power steering belt).
- Belt noise that changes with engine speed.

Before you start: locate belt routing
- Most D22 trucks have a belt routing diagram sticker under the hood or on the radiator support. If not, photograph the belt routing before removal or draw a quick diagram. Do not rely on guessing.

Step-by-step replacement (accessory/drive belt)
1) Preparation
- Gather tools, new belt, stand clear area.
- If access is tight, raise the front and support on jack stands (securely). Battery disconnect optional (recommended for safety).
- Locate belt routing diagram; if not found, take clear photos from multiple angles of the belt routing.

2) Inspect current belt and components
- With engine off, examine belt surfaces: check inside ribs for cracks, frays, glazing, missing chunks, or oil contamination.
- Rotate each accessible pulley by hand (with engine off): they should spin freely and quietly, with no play or wobble. If a pulley bearing is noisy or tight, plan to replace it.
- Inspect tensioner: automatic tensioner should apply tension and not be ejected or loose. If it’s noisy or weak, replace it.
- Inspect pulley alignment: pulleys should be in the same plane; misalignment causes belt edge wear.

3) Release belt tension and remove old belt
- Find the tensioner. For a spring (automatic) tensioner there will be a square or hex boss for a ratchet or breaker bar.
- Insert a long-handled ratchet or breaker bar into the tensioner boss and rotate it to relieve tension (direction depends on engine model — typically clockwise). Hold it in the released position and slip the belt off one of the easiest pulleys (usually alternator or idler). Slowly release the tensioner back to its resting position.
- If you have a manual tensioner, loosen the lock bolt(s) and move the tensioner to relieve tension, then remove the belt.
- Remove the belt from all pulleys and take it out.

4) Inspect accessory pulleys and replace if needed
- Spin each pulley again. Replace any idler or tensioner bearings that feel rough, have play, or are noisy.
- Clean pulley grooves with a rag; remove oil/grease. Do NOT use heavy solvent that could damage seals — just wipe and use light degreaser if needed, then dry.
- If any accessory (A/C, alternator, power steering) pulley wobbles, it needs repair/replacement.

5) Compare old and new belt
- Lay them side by side to verify identical length and rib count. If the new belt is visibly different, do not install — get the correct belt.

6) Route the new belt
- Follow the routing diagram exactly. Keep the belt seated correctly in all pulley grooves.
- Leave an easy-to-remove pulley (typically alternator) for last.

7) Tensioning and installing the new belt
- For automatic tensioner: rotate the tensioner again to open its arm, slip the belt over the remaining pulley, and slowly release the tensioner so it takes up slack. Confirm the belt is fully seated on all pulley grooves and centered.
- For manual tensioner: tighten the belt to the specified deflection or tension. A rule‑of‑thumb for manual belts (if you lack a gauge): push down at the midpoint of the longest run with about 10–15 lb (4.5–7 kg) of force; deflection should be about 8–12 mm (check your manual). After setting, tighten the tensioner lock bolt, then re-check deflection.
- Do not overtighten — this damages bearings.

8) Final checks before starting
- Verify belt sits flush in each pulley. Check alignment visually and by running your finger (engine off) along the ribbed side — ribs should be centered.
- If you replaced pulleys/tensioner, torque the mounting bolts to manufacturer spec. If you don’t have the manual: clean and clamp, and torque to a reasonable value for that bolt size (but best to get the exact numbers). Typical idler/tensioner bolt torque values are in the 35–70 Nm range depending on engine — consult the service manual for your engine.

9) Start engine and observe
- Start engine and watch belt for correct tracking and to ensure it does not slip or walk off pulleys.
- Listen for unusual noises. Let the engine idle and then increase RPM slightly; watch for belt wobble or vibration.
- Check charging system (battery light off, multimeter ~13.5–14.5V at idle) and A/C/power steering operation as applicable.

10) Road test and recheck
- Short drive ~10 minutes under varied engine loads. After cool-down, recheck belt tension and pulley bolts. Automatic tensioners may settle; recheck after the first few heat cycles.

What can go wrong (and how to avoid/diagnose)
- Belt slips or squeals after replacement: likely incorrect routing, misaligned pulley, oil contamination, or weak/failed tensioner. Re-check routing, belts for contamination, and replace tensioner if weak.
- Belt walks off pulleys: misalignment of an idler or accessory or incorrect belt size. Inspect pulley alignment and correct or replace misaligned pulley.
- Accessory failure after replacement (no charging, hard steering): belt may be installed on wrong pulley path (skipping water pump or alternator), or a pulley bearing seized. Verify routing and inspect pulleys.
- Tensioner bolt loosened or torque not correct: tensioner can spin or slip — re‑torque to spec.
- Damaging the crank pulley: do not attempt to remove or torque the crankshaft pulley for a simple belt change.
- Oil/grease contamination: if the belt gets oil on it, replace the belt and repair the leak. Wiping an oil‑soaked belt does not restore grip.

Maintenance tips and recommended parts
- Replace tensioner and idlers when they show symptoms or around every other belt change (belt life ~60k–100k km depending on conditions).
- If the engine has two belts (separate A/C and power steering belts), replace both if worn.
- Keep a short spare belt in the trunk for emergency replacement.
- When changing belt, inspect/replace accessories with bad bearings or play.

Engine‑specific notes (D22 variations)
- D22 trucks come with different engines in different markets. The accessory belt routing and tensioner type can vary by engine (GA16, KA24DE, YD25, etc.). Always verify the belt routing diagram for your specific engine — the procedure above applies in general but routing, tensioner access point, and which accessories are driven will vary.
- Some engines use a separate belt for power steering or A/C — identify which belt you are replacing.

Final checks and summary
- Confirm proper belt routing, tension, and pulley condition.
- Start engine, check for noise and charging, road test, and recheck after heat cycle.
- If anything seems off — squeal, misalignment, overheating (if water pump driven by the belt): stop and diagnose before driving long distances.

If you want, I can give a short checklist you can print and bring with you to the job, or give specific belt part numbers and exact pulley/tensioner locations for your exact engine code and year — but you said no questions, so I stopped here.
rteeqp73

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