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NISSAN FRONTIER 2 & 4WD AUTOMATIC

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1. 3651 N Highway 89 Chino Valley AZ 86323 928 636 7080 www p a g net NISSAN FRONTIER 2 amp 4WD AUTOMATIC amp MANUAL TRANS KING amp CREW CAB MODELS 3 BODY LIFT KIT INSTALLATION INSTRUCTIONS 2005 2011 KIT 40083 A WARNING Installation of a Performance Automotive Group body lift kit will change the vehicle s center of gravity and handling characteristics both on and off road You must drive the vehicle safely Extreme care must be taken to prevent vehicle rollover or loss of control which could result in serious injury or death Avoid sud den sharp turns or abrupt maneuvers and always make sure all vehicle occupants have their seat belts fas tened A WARNING Before you install this kit read and understand all instructions warnings cautions and notes in this instruction sheet and in the vehicle owner s manual A CAUTION Proper installation of this kit requires knowledge of the factory recommended procedures for removal and installation of original equipment components We rec ommend that the factory shop manual and any special tools needed to service your vehicle be on hand during the installation Installation of this kit without proper knowledge of the factory recommended procedures may affect the performance of these components and the safety of the vehicle We strongly recommend that a certified mechanic familiar with the installation of sim ilar components install this kit A WARNING DO N
2. a Mark and cut skid plate as shown Mark amp Cut o TIGHTEN six bumper bolts Skid Plate p Install two bumper side supports onto driver and passenger side of bumper with two bolts AFTER CUT 32 Frontier Kit 40083 b Install kit u nut 5 16 onto two kit spacers 2 x 3 x 1 Kit U Nut 5 16 kit Spacer 2 x 3 x 1 c Install two kit spacers 2 x 3 x 1 onto bumper support with two front skid plate bolts Front Skid Plate Bolts 2 x 3 x 1 Kit Bolts 5 16 x 1 kit Washers 5 16 USS d Install skid plate onto crossmember with two rear skid plate bolts e Install skid plate onto two kit spacers 2 x 3 x 1 with two kit washers 5 16 USS and two kit bolts 5 16 x 1 Rear Skid Plate Bolts 33 4 Lower fascia a Mark and cut lower fascia as shown BEFORE Mark amp Cut CUT b Install lower fascia onto bumper with four screws and two bolts Front Bumper Screws a amp Bolts aa ie Lower Fascia Frontier Kit 40083 After Completing Installation Inside Cab 1 Install airbag fuse and fuse cover Glove Box Engine Compartment 1 Install battery into vehicle with battery tie downs 2 Connect both battery cables Connect positive cable first then negative cable s l Positive Cable i Fii i I 1 7 z k g WD Pi GNN Tr BT at aa f a
3. 1 4 SAE and kit nut 1 4 Se ae Nylock LE TAM Power Steering Cooler Line Kit Bolt SS 1 4 X 1 d iL Kit Washers al 1 4 SAE Kit Nut arm m 1 4 Nylock Kit Bracket 2 Z Shaped i Wi eat P i ee ie dii i 5 r zA p Bolt Psgr Side Frame 10 Fan shroud amp radiator d Remove two rubber isolators from two radiator a Install radiator onto core support brackets brackets and install onto large hole two kit spac ers 2 x 3 x 1 b Remove kit ties from core support and AC con densor Radiator aS AC i Condenser E W k e Install two radiator brackets onto core support with two bolts A CAUTION CAREFULLY bend AC line Over bending AC line may cause the line to crack and or leak 27 Frontier Kit 40083 f Install two kit u nuts 5 16 onto two kit spac ers 2 x 3 x 1 Kit Spacer 2 x 3 x 1 Kit U Nut 5 16 Radiator Bracket Bolt Core Support g Install radiator onto radiator brackets with two kit washers 5 16 USS and two kit bolts 5 16 x 1 kit Washers 5 16 USS Kit Bolts 5 16 x 1 a Radiator Brackets h Install fan and fan clutch onto pulley with four nuts Fan amp Fan Clutch 28 I Install fan shroud and electric fan onto radiator with three bolts Radiator Fan Shroud j Connect AC condenser and electric fan wiring harnes
4. ensuring marks on lower steering shaft and rack amp pinion are aligned Alignment Lower Steering Shaft Marks Saas BaF Bolt Kit Extension Saag 2 4 Steering kit Bolt 3 8 x 1 1 4 s Rack amp Pinion c Apply a small amount of kit Loctite onto fac tory bolt and kit bolt 3 8 x 1 1 4 d Install and TIGHTEN bolts to 33 lb ft 6 Install engine wiring harness onto engine and wheel well with two clips Electrical Tape Clips Wiring Harness Frontier Kit 40083 7 Power steering reservoir e Remove two factory hose clamps and heat shield from hose a Remove cap and drain contents of reservoir into clean drain pan or bucket Heat Shield i es i b Position drain pan or bucket beneath large ae diameter hose on passenger side of engine Reservoir _ Large Hose f Install heat shield and two factory clamps onto kit hose 5 8 x 14 Heat Shield c Remove clamp and large diameter hose from engine and drain contents into drain pan or Large Dia Hose kit Hose 5 8 x 14 This kit is supplied with two kit clamps 10 hose if the two factory clamps above do not fit over kit hose 5 8 x 14 g Install kit hose 5 8 x 14 onto engine and res d Remove clamp and large diameter hose from en ervoir with two factory clamps reservoir Reservoir Clamp Large Dia Hose 23 Frontier Kit 40083 h Install brac
5. its body lifts and cannot assume responsibility for the customer s choice of wheels and tires Refer to your owner s manual for recommended tire sizes and warn ings related to the use of oversized tires Larger wheel and tire combinations increase stress and wear on steering and suspension components which leads to increased maintenance and higher risk for component failure Larger wheel and tire combinations also alter speedometer calibration braking effectiveness center of gravity and handling characteristics Consult an experienced local off road shop to find what wheel and tire combinations work best with your vehicle Frontier Kit 40083 Kit Parts List All warranty information instruction sheets and other documents regarding the installation of this product Qty Description must be retained by the vehicle owner Information contained in the instructions and on the warranty card 10 Block 3 x 2 will be required for any warranty claims The vehicle 4 Block 3 x 3 owner needs to understand the modifications made to 10 Bolt 1 2 x 1 1 2 the vehicle and how they affect vehicle handling and olt ade performance Failure to provide the customer with this 7 Bolt 1 4 x 1 information can result in damage to the vehicle and Bolt 10mm x 120mm ie severe personal injury Bolt 12mm x 180mm Bolt 12mm x 30mm Bolt 3 8 x 1 1 4 Bolt 5 16 x 1 Bolt 6mm x 30mm Bracket 2 step w stud Bracke
6. Accidental deployment of the air bag can result in seri ous personal injury or death To avoid accidental deployment during installation of the lift kit the Supple mental Restraint System SRS or airbag must remain deactivated Do not allow anyone near the airbag dur ing installation Refer to the factory service manual or owner s manual for the recommended procedure to disable the SRS After kit installation the SRS must be reactivated before driving the vehicle A CAUTION If the following step is not performed the airbag clock spring could be damaged Do not turn the steering wheel while the steering shaft is disconnected a Strap steering wheel to prevent accidental movement b Mark lower steering shaft in relation to rack amp pinion shaft as shown c Remove bolt and slide lower steering shaft up and off of rack amp pinion shaft Lower Steering Shaft Rack amp Pinion Frontier Kit 40083 10 Remove two nuts and brake line bracket from lower e Remove four bolts and boot ring from floor driver side firewall Bracket if 9 ae ease f Remove two inner shift boots from shift lever Driver Side oOo a a and floor Firewall Inner Shift Inside of Vehicle eco 1 Manual transmission Shift Lever a Ss a Pull up and remove cup holder trim panel from D o center console Inner Shift b Pull up and remove shift boot trim panel from Boot center console 7 g Remove two zi
7. NOT TIGHTEN Upper i Plastic Step kit Hose 1 x 3 FRONTIER Fuel Filler ___ i kit Clamp 20 Hose o Connect two license plate wiring harnesses onto rear bumper c Install kitextension fuel filler into kit hose 1 x 3 with kit clamp 20 hose DO NOT Plate Wiring Harness Kit Extension Fuel Filler kit Hose 1 x 3 kit Clamp p Install spare tire onto vehicle 20 Hose 17 Frontier Kit 40083 d Install fuel filler hose onto kit extension fuel filler with clamp DO NOT TIGHTEN Underside of Vehicle 1 Parking brake cables a Install two Ait brackets 2 1 2 c shaped onto bottom center of cab with two nuts b Install two parking brake cables onto two kit f EA OR a brackets 2 1 2 c shaped with two kit bolts 1 on Sa CA TO 4 x 1 four kit washers 1 4 SAE and two kit Fuel Filler er Hose oe o Align top of fuel filler with bed side and install fuel filler hose onto fuel tank with clamp f Install vent hose and clip onto fuel filler vent tube Adjust fuel filler hose and kit hose 1 x 3 and install fuel filler onto bed with bolt nuts 1 4 Nylock Kit Brackets 2 1 2 kit Bolts 1 4 x 1 kit Washers 1 4 SAE FV i Kit Nuts m ay 1 4 Nylock Park Brake Cables 2 Crush blocks A WARNING Welding should be performed by a certified welder or welding sh
8. ea r l y l KET a aa me 5 IDMAN MANANE EPNER EIEEEI EEA EE TUT i ES Remove any hoses clipped onto fan shroud m Pull fan shroud and electric fan up and out of Stopcock vehicle 7 Frontier Kit 40083 n Remove two bolts from AC condenser and b Remove three bolts and bracket from passenger upper radiator side wheel well Radiator a Bracket Condenser o Using kit ties hang AC condenser from upper core support Core P Support F Kit Ties AC Condenser p Pull radiator up and out of vehicle 6 Engine wire harness 5 Power steering reservoir a Remove or cut electrical tape covering wiring a Remove power steering reservoir from bracket harness clip on passenger side wheel well Reservoir b Remove wiring harness from upper clip and lower clip located on passenger side engine bracket Electrical Tape Bracket Wiring Harness 8 Frontier Kit 40083 7 Remove bolt power steering cooler line and bracket from driver side frame rail Driver Side Frame Bolt Cooler Line 8 ABS sensors a Remove or cut two ABS sensor harness clips from driver side wheel well b Disconnect driver and passenger ABS sensor harnesses from two spring perches ABS Harness Spring Perch c Remove two bolts two brackets and ABS har nesses from two spring perch brackets ABS Harness Bracket 9 Steering Shaft A WARNING
9. of bumper support 3 Mark Bumper Support Top Bolt g Cut or drill two holes into bumper support corre sponding to upper two bolts Bumper Mark Or Drill Hole AFTER CUT h Install bumper support onto two kit bracket front bumper studs with two kit washers 1 2 SAE and two kit nuts 1 2 Nylock DO NOT TIGHTEN Support Pa O Kit Nuts 1 2 Nylock Kit Washers 1 2 SAE Kit Bracket SN ee re A F Bumper i Install bumper support onto two kit brackets front bumper with two kit bolts 1 2 x 1 1 2 four kit washers 1 2 SAE and two kit nuts 1 2 Nylock Kit Bolts 1 2 x 1 1 2 Kit Washers 1 2 SAE Kit Nuts 1 2 SAE Top Of Bumper Support j TIGHTEN two kit bolts 1 2 x 1 1 2 and two kit nuts 1 2 Nylock on two kit bracket front bumper studs k Install bumper onto upper bumper support with four bolts DO NOT TIGHTEN I Connect two fog light wiring harnesses if equipped Frontier Kit 40083 m Bend lower bumper brackets to meet lower 2 Grill bumper support brackets f a Install grill onto core support with four turn clips BEFORE __ ae or and four lower clips BEND i Bumper Bracket Bumper Support l Brackets o b Install top of grill onto core support with six pop up clips n Install bumper onto lower bumper support brack ets with two bolts Grill 3 Skid plate
10. License Plate Wiring Harness Bumper Bracket Install Kit Cab 1 Prepare to lift cab from frame a Loosen but DO NOT REMOVE cab mounting bolts on driver side Bumper Bracket Lower Hardware Loosen Bolts At These Mounts d Depress clips and remove upper plastic step from bumper Rear Bumper Clips Upper MES OS Plastic re TE Step lt a The number of cab mounting bolts may vary with the length of the cab 12 Frontier Kit 40083 b Remove bolt and lower hardware from each cab b Install kit blocks onto upper bushings on each mount on passenger side cab mount as shown below Bolt Lower Hardware Remove Bolt Kit Block From These Mounts 3 x 2 kit Block 3 x 3 s Kit Block 3 x 2 Crew Cab MEE EA ONLY Cab Mount Kit Block 3 x 3 NOTE Lower cab onto kit blocks Retain lower hardware from each cab mount Lower l hardware will be re used Install lower hardware and kit bolt 12mm x 180mm on each cab mount DO NOT TIGHTEN A WARNING Use extreme caution when lifting body from frame To prevent serious personal injury ensure the lifting device is securely placed Keep your hands out from between the body and frame A CAUTION Continually check hoses wires lines etc to be sure that everything is flexing properly and not binding or damage to the vehicle could result Be especially care ful of the a c hoses at the fire wal
11. OT combine suspension body or other lift devices Use of vehicle with combined lifts may result in unsafe and or unexpected handling characteristics 4 WARNING This kit should only be installed on a vehicle that is in good working condition Before you install the kit thor oughly inspect the vehicle for corrosion or deformation of the sheet metal around the factory body mounts If the vehicle is suspected to have been in a collision or misused do not install this kit Off road use of your vehicle with this kit installed may increase the stress applied to the factory body mounts We do not recom mend that any vehicle with a body lift kit installed be involved in any extreme off road maneuvers such as jumping Failure to observe this warning may result in serious personal injury and or severe damage to your vehicle A WARNING Many states and municipalities have laws restricting bumper heights and vehicle lifts Consult state and local laws to determine if the changes you intend to make to the vehicle comply with the law Z WARNING The installation of larger tires may reduce the effective ness of the braking system A WARNING Always wear eye protection when operating power tools A WARNING Before you install this kit block the vehicle tires to pre vent the vehicle from rolling A WARNING Accidental deployment of the air bag can result in seri ous personal injury or death To avoid accidental deployment d
12. ackets from bumper crossmember as shown below Kit Bolt 10 x 120mm Washer e Repeat previous steps on driver side of bed f Set bed to cab spacing according to previous measurement g Remove each kit bolt one at atime and apply a small amount of kit Loctite onto threads Install Ait bolt and washer TIGHTEN kit bolt to 55 ft Ibs Mark amp Cut Rear of Vehicle 1 Spare tire a Lower and remove spare tire according to vehi cle owner s manual Saws All b Remove two clips and winch tunnel from bed c Remove two clips and winch horn from cross member Winch Tunnel Clips Cross SS a b Install cut bumper crossmember into two kit Member brackets rear bumper Winch Horn 15 Frontier Kit 40083 c Install two kit brackets rear bumper onto frame rails with six bolts Align bumper crossmember in two kit brackets rear bumper Snug bolts but DO NOT TIGHTEN Kit Bracket R Bumper Cross Member d Install two kit brackets rear bumper support onto two kit brackets rear bumper with four kit bolts 1 2 x 1 1 2 eight kit washers 1 2 USS and four Ait nuts 1 2 Nylock Snug but DO NOT TIGHTEN e Through center of four holes in two kit brackets rear bumper support mark bumper cross member Kit Bracket R Bumper Driver Mark Crossmember kit Bracket R Bumper Support f Drill four 1 2 holes into bumper cro
13. diator Radiator a Remove two bolts and two brackets from radia tor and top of core support ran Shroud adiator i A 5 e Depress two clips along bottom of fan shroud and remove lower fan shroud Fan Shroud Brackets Clips b Disconnect and remove two wiring harnesses from electric fan and AC condensor Lower Fan Shroud AC Condenser Wiring Harnesses Fan 6 Frontier Kit 40083 f Remove four nuts fan clutch and fan from pul j Once all coolant has been drained remove ley clamps upper and lower radiator hoses Clamp amp Upper Hose Fan amp Fan Clutch NOTE Pulley may shift due to belt tension This will not harm any components g Position clean drain pan or bucket beneath radi ator stopcock A WARNING lf the engine cooling system is hot the coolant will be EA HOT and UNDER PRESSURE To prevent serious _ personal injury wait until the cooling system is com k Remove two clamps and two transmission cool pletely cool before removing the cap and or hoses from ant lines if equipped from bottom of radiator the radiator Clamp amp Lower Hose Trans Cooler Lines amp Clamps h Remove radiator cap i Open radiator stopcock and drain coolant into clean drain bucket or pan HE Radiator AA Sll l s Radiator ty tate r ania site on meet pan _ Screen ates r es r woo a
14. er Kit 40083 f Remove rubber isolator from bracket and install j Install bracket onto lower driver side radiator onto large hole of kit spacer 2 x 3 x 1 with bolt DO NOT TIGHTEN ig ay A n Driver Side Ss w S S i wn gt Bracket Taj ae Ti r gt a il z a i tie i j B w ii i Be ow B a i lii 1 hg gt i F ma F Kit Bracket Radiator Driver Bolt g Install kit spacer aP x 3 xX 1 onto driver side k Install bracket onto kit spacer 2 x 3 x 1 with radiator pin kit washer 5 16 USS and kit bolt 5 16 x 1 Kit Spacer 2 x 3 x 1 Kit Washer 5 16 USS 2 x 3 x 1 Isolator iN S See Radiator h Install kit u nut 5 16 onto kit spacer 2 x 3 x I TIGHTEN lower bolt and kit bolt 5 16 x 1 1 m Repeat above steps for passenger side bracket Kit U Nut 5 16 kit Spacer 2 x 3 x 1 i Mark and cut driver side bracket to clear radia tor BONIS kit Spacer ALUAN TNA EAIN p MANANA ANAT TAME j UNUMI Mark amp Cut 26 Frontier Kit 40083 9 Power steering cooler line c Slightly bend AC line down on AC condenser and install AC condenser onto radiator with two a Install kit bracket 2 Z shaped onto passenger bolts side frame with bolt b Install power steering cooler line onto kit tiene p bracket 2 Z shaped with kit bolt 1 4 x 1 m TY tae two kit washers
15. f the bed 2 Remove bolt and washer from each bed mount on passenger side Remove Bolt From These Mounts Bolt Bed Mount NOTE Retain washer from each bed mount Washers will be re used A WARNING Use extreme caution when lifting the bed from the frame To prevent serious personal injury ensure the lifting device is securely placed Keep your hands out from between the bed and frame A CAUTION To prevent damage to the vehicle while lifting the bed continually check hoses wires brake lines etc to ensure everything is flexing properly and not binding Ensure clearance between bed and cab is maintained 3 Bed passenger side a Using a hydraulic floor jack and a wood block slowly lift passenger side of bed a little more than 3 b Install a kit block 3 x 2 on each bed mount kit Block 3 x 2 Frontier Kit 40083 c Lower bed onto kit blocks 2 Rear bumper d Install kit bolts 10mm x 120mm and factory WARNIN washers onto each bed mount DO NOT 2 TIGHTEN The following procedure is intended only to enhance the appearance of the vehicle The rear bumper will no longer be rated for towing of any kind Towing with the ts rear bumper after it has been lifted can result in death serious personal injury or damage to the vehicle Tow ing after the bumper has been lifted should be accom plished using a rated Class IIl receiver type hitch a Mark and cut two bumper br
16. ith kit washer 1 4 SAE and kit bolt 6mm x 30mm kit Bolt 6 x 30mm kit Washer 1 4 SAE Kit Spacer 250 3 F i ee _ i ee s e i Driver Side N EN Bracket sA A h TIGHTEN two clamps and intake chamber bolt C ty Vi I Install vent hose onto intake chamber with clamp Front of Vehicle 1 Front bumper a Apply a small amount of kit Loctite 6ml bottle onto threads of two bolts and install kit bracket front bumper driver onto driver side frame rail with two bolts DO NOT TIGHTEN Kit Bracket F Bumper Driver Bolts b Repeat above step for kit bracket front bumper passenger c Apply a small amount of kit Loctite 6ml bottle onto threads of two kit bolts 12mm x 30mm and install kit bracket front bumper driver onto bottom of frame rail with two kit bolts 12mm x 30mm and two kit washers 12mm Kit Bracket F Bumper Driver Frame Rail Kit Bolts 12 x 30mm kit Washers 12mm d Apply a small amount of kit Loctite 6ml bottle onto threads of two bolts and install tow hook and kit bracket front bumper passenger onto bottom of frame rail with two bolts Tow ook al Frontier Kit 40083 e TIGHTEN six factory bolts and two kit bolts 12mm x 30mm f Position lower mount holes of bumper support onto kit bracket front bumper studs and mark interference between top bolts and backside
17. ket onto passenger side wheel well 8 Radiator brackets with three bolts As A a Remove bolt and driver side bracket from radia Bracket A am Vl rE tor Radiator mn i Install reservoir onto bracket Reservoir Bracket A CAUTION Reuse power steering fluid ONLY if fluid is not contam inated Follow vehicle owner s manual instructions for refilling power steering fluid Contaminated or improper fluid may cause damage and or failure j Refill reservoir using power steering fluid from drain pan or bucket 24 Frontier Kit 40083 b Mark and cut bracket as shown c Position kit bracket radiator driver onto l bracket and mark bracket through two holes in Driver Side kit bracket Ensure kit bracket is set to 3 Driver Side Bracket Mark amp Drill Here Psgr Side Before Cut Set Kit Bracket Onto Dvr Side Radiator Bracket To 3 Hole To Hole ppRracne Radiator AFTER CUT Driver d Drill two 1 4 holes into bracket corresponding to holes in Ait bracket radiator driver e Install Ait bracket radiator driver onto bracket with two kit bolts 1 4 x 1 four kit washers 1 4 SAE and two kit nuts 1 4 Nylock Ensure kit bolt heads are facing out 1 ae Tig r ee Ms ee Driver Side Bracket kit Bolts 1 4 x 1 kit Washers Kit Nuts 1 4 Nylock kit Bracket Radiator Driver 25 Fronti
18. l g Battery i Tie Downs a AAT a f z t i an E B Fn gt B i qp w hii 4 Negative Cable 34 Miscellaneous 1 Apply kit label warning onto dashboard in plain sight of all vehicle occupants 2 Check all fasteners to ensure they are tight 3 Ensure all wires hoses cables etc are properly connected and there is ample slack 4 Adjust headlights A WARNING lf the engine cooling system is hot the coolant will be HOT and UNDER PRESSURE To prevent serious personal injury wait until the cooling system is com pletely cool before removing the cap from the radiator Remove radiator cap Start engine and top off cool ing system Purge air from cooling system according to vehicle owner s manual instructions Install radia tor Cap Dynamic Vehicle Check 1 Check steering in both directions to ensure that there is no bind Check operation of clutch brake system and parking brake Check operation of transmission and transfer case Ensure there is full engagement in all gears and 4WD ranges Check battery connections and electrical component oper ations Test drive vehicle A WARNING Retorque all fasteners after 500 miles and after off road use All body lift components should be visually inspected and fasteners retorqued during routine vehi cle servicing A CAUTION Performance Automotive Group does not recommend any particular wheel and tire combinations for use with
19. l the belt pulley and at the core support Ensure brake lines stretch while lifting Bending the lines to gain ample slack may be necessary Be extremely careful not to kink the lines 2 Cab passenger side a Position a hydraulic floor jack and a wood block under passenger side of cab under the body seam Slowly lift cab just enough to install a kit gt Crew Cab block on top of factory upper bushing Tn ONLY A WARNING The kit blocks must be installed in addition to the fac tory upper and lower bushings Installing the kit blocks without the factory upper and lower bushings could result in damage to the vehicle or serious personal injury Kit Bolt 12mm x 180mm kit Washer 1 2 USS Lower Hardware 13 Frontier Kit 40083 NOTE Lower hardware varies between each body mount and can include rubber bushings and or washers 3 Cab driver side a Repeat previous steps on driver side of cab b Set cab to bed spacing according to previous measurement c Remove each kit bolt one at atime and apply a small amount of kit Loctite onto threads Install kit bolt kit washer 1 2 USS and lower hardware TIGHTEN kit bolt to 55 ft Ibs Hardware Kit Bolt 12 x 180mm Kit Washer Bed 1 Prepare to lift bed from frame a Loosen but DO NOT REMOVE bed mounting bolts on driver side Loosen Bolt At These Mounts NOTE The number of bed mounting bolts may vary with the length o
20. lignment marks along shift lever just below bend Kit Extension Shift 5 8 x 3 Shift Assembly Shift Assembly Cut Mark Alignment Marks Alignment Mark d Grind welds smooth and install shift lever assembly onto shift tower with three bolts b Cut shift lever along cut mark A CAUTION Use wet rags to insulate plastic shift assembly compo nents from welding heat Damage may occur to shift lever assembly and or components if care is not taken to protect components from heat while welding A WARNING Welding should be performed by a certified welder or welding shop Improper welding can damage vehicle and or kit parts and cause serious personal injury Shift Lever Assembly e Install shift tower boot onto shift tower using kit ties Zip Zip Ties Shift Tower Boot 20 Frontier Kit 40083 f Install two inner shift boots onto shift lever and Engine Compartment floor with boot ring and four bolts 1 Install heater core tube onto firewall with two nuts 5 i ym Boot Ring g Install wiring harness and bracket onto floor with bolt 2 Install AC line and bracket onto driver side firewall E with two bolts Wiring Harness AC Line amp Bracket h Install shift boot trim panel onto center console i Install cup holder trim panel onto center console 3 Brake line bracket Shift Boot F a Install kit bracket 2 w stud onto lower hole of Pa
21. milar reciprocating cutting blade tool 5 Park vehicle on a clean dry flat level surface and block tires so vehicle cannot roll in either direction Engine Compartment 1 Disconnect both battery cables Disconnect nega tive cable first then positive cable 2 Remove battery tie downs and battery from vehicle and place on floor or ground Positive Cable Battery Tie Downs a F Negative Cable Inside Cab 1 Airbag Fuse NOTE The location of the airbag fuse may vary check the owner s manual a Remove fuse cover b Remove airbag fuse Glove Box Frontier Kit 40083 Prepare to Install Kit Measurements 1 Measure and record distance between front bumper and fenders Driver Side Passenger Side Measure and record distance between rear bumper and bed Driver Side Passenger Side Measure and record distance between cab and bed Driver Side Passenger Side Front of Vehicle 1 Grill a Remove six pop up clips from top of grill and core support b Turn four turn clips 45 depress four lower clips and remove grill from core support 2 Front Bumper a Remove four screws and two bolts and lower fascia from fascia Fascia Lower Screws amp Bolts Bolts Frontier Kit 40083 c Remove four bolts and skid plate from front f Remove six bolts four upper and two lower and bumper and crossmember front bumper from core support and bumper sup
22. nel _ ry lower driver side firewall with bolt Driver Side Shift Knob Firewall Nut Cup Holder J Kit Washer j Install shift knob onto shift lever 1 4 SAE Kit Nut 1 4 Nylock Brake Line Bracket b Install Ait bracket 2 step w stud onto upper hole of lower driver side firewall with bolt 21 Frontier Kit 40083 c Install brake line bracket onto two kit brackets with two kit washers 1 4 SAE and two kit nuts 1 4 Nylock kit Washer 1 4 SAE Kit Nut 1 4 Nylock Brake Line Bracket Kit Bracket 2 Step W Stud ABS sensors a Install kit bracket 2 w stud onto driver side spring perch with bolt b Install ABS harness and bracket onto kit bracket 2 w stud with kit washer 1 4 SAE and kit nut 1 4 Nylock ABS Harness amp Bracket e Kit Bracket 2 W Stud Spring Perch kit Washer 1 4 SAE Kit Nut 1 4 Nylock c Repeat above steps for passenger side ABS harness and bracket 22 5 Steering shaft A WARNING Verify the steering extension is securely installed as specified in the instructions Failure to do so may cause steering malfunction resulting in property dam age or serious personal injury a Install kit extension steering into lower steer ing shaft Ensure marks on lower steering shaft and rack amp pinion are aligned b Install rack amp pinion into kit extension steer ing
23. op Improper welding can damage vehicle and or kit parts and cause serious personal injury a h TIGHTEN kit clamps 20 hose and clamps i Install fuel cap a Remove four rubber pads from two frame rails Install rubber pad on top of each kit spacer 2 x 3 x 2 b 18 Frontier Kit 40083 c Install four Ait spacers 2 x 3 x 2 between frame rail and bed rail and weld kit Spacers 2 x 3 x 2 onto frame Bed Rail te P Fe m Fis gel ee UL AE j Frame Rail 3 Exhaust ground strap a Install kit bracket 3 w stud onto exhaust with nut b Install ground strap onto kit bracket 3 w stud with kit washer 1 4 SAE and kit nut 1 4 Nylock Ground Strap kit Washer 1 4 SAE Kit Nut 1 4 Nylock Kit Bracket 3 W Stud 4 Wire harness a Install kit bracket 3 w stud onto passenger frame rail with bolt b Install bracket and wiring harness onto kit bracket 3 w stud with Ait washer 1 4 SAE and kit nut 1 4 Nylock Bracket amp Wiring Harness Kit Washer 1 4 SAE Kit Nut 1 4 Nylock Kit Bracket 3 W Stud Psgr Side Frame c Install plastic cover onto bracket Plastic Cover Harness 19 Frontier Kit 40083 Inside of Vehicle c Position kit extension shift 5 8 x 3 between two cut halves of shift lever and align previously place a Mark cut and a
24. p ties and shift tower boot from Shift Boot 7 shift tower Panel rT Shift Tower Shift Knob Zip Ties Cup Holder Panel Shift Tower Boot remove shift knob from shift lever h Remove three bolts and shift lever assembly d Remove bolt and wiring harness bracket from from vehicle floor Wiring Harness amp Bracket Shift Lever Assembly 10 Frontier Kit 40083 Underside of Vehicle Rear of Vehicle 1 Wire harness 1 Fuel filler a Remove plastic cover from passenger side wir a Open fuel door and remove fuel cap ing harness behind front wheel Wiring Harness Plastic Cover b Remove bolt bracket and wiring harness from frame rail Fiel Filler Wiring Bolt Bolt amp Bracket Bed Bracket Psgr Side Frame Ea go c Remove vent clip and hose from fuel filler vent tube 2 Remove two nuts and two parking brake cables from bottom center of cab d Remove two clips clamp filler hose and fuel filler from fuel tank and vehicle Vent Clip amp Hose Park Brake BS mF Fuel Filler Cables Ii E Hose 2 Remove nut and ground strap from exhaust 11 Frontier Kit 40083 3 Rear bumper e Depress clips and remove lower plastic step from bumper a Remove wiring harness clip from bed rail Plastic Step f Remove six nuts six studs and bumper from b Disconnect two license plate wiring harnesses bracket and crossmember from rear bumper
25. port Skid Plate d Disconnect two fog light wiring harnesses if equipped e Remove two bolts and two side supports from driver and passenger inside front bumper Front Bumper Bottom Bolts Side Support g Remove four bolts and bumper support from frame rails Bumper Support 4 Frontier Kit 40083 Engine Compartment d Remove two bolts from intake chamber 1 Airbox a Disconnect wiring harness from airbox cover Wiring Harness Intake Chamber lt TE aN Intake ae e Loosen clamps on intake and throttle body and Airbox remove intake Cover Airbox b Remove two bolts and engine cover from Clamp engine Throttle Body Clamp a Intake f Remove two clips airbox cover and airbox filter 2 Remove two nuts and metal heater core tube from firewall ber Heater Tube Vent Hose Clamp Intake Chamber 5 Frontier Kit 40083 3 Remove two bolts bracket and AC line from driver c Remove clamp and overflow hose from radiator side firewall Radiator Overflow AC Line Hose amp Bracket d Remove three bolts from fan shroud electric f i i 4 Fan shroud amp radiator fan and top of radiator A WARNING If the engine cooling system is hot the coolant will be HOT and UNDER PRESSURE To prevent serious personal injury wait until the cooling system is com pletely cool before removing the cap and or hoses from the ra
26. ses AC Condenser Wiring Harnesses Electric Fan k Install two transmission cooler lines onto radia tor with two clamps if equipped Trans Cooler Lines amp Clamps Radiator I Install lower fan shroud onto fan shroud with two clips Fan Clips Lower Fan Shroud Frontier Kit 40083 m Install upper and lower radiator hoses with two 11 Airbox clamps a Install air filter into airbox Clamp amp ao lt Upper Hose amp b Ns D b Install airbox cover onto airbox with two clips c Connect wiring harness onto airbox cover Wiring Harness Airbox Cover d Install intake onto throttle body and airbox cover with two clamps DO NOT TIGHTEN clamps Clamp amp Lower Hose ADON Clamp Throttle Body Clamp Intake Clamp e Install intake chamber onto passenger side bracket with bolt DO NOT TIGHTEN Overflow Psgr Side Bolt o Clip hoses onto fan shroud if necessary A CAUTION Reuse coolant ONLY if coolant is not contaminated Follow vehicle owner s manual instructions for refilling coolant Contaminated or improper coolant may cause damage and or failure Intake Chamber p Refill radiator using coolant from drain pan or bucket f Install kit spacer 250 between intake cham ber mount and driver side bracket q Install radiator cap 29 Frontier Kit 40083 g Install intake chamber onto driver side bracket w
27. ssmember corresponding to previously made marks g Install two kit brackets rear bumper support onto bumper crossmember with four kit bolts 1 2 x 1 1 2 eight kit washers 1 2 USS and four kit nuts 1 2 Nylock DO NOT TIGHTEN Kit Bracket R Bumper Driver kit Bracket R Bumper dete Kit Bolts p 1 2 x 1 1 2 kit Washers 1 2 USS kit Nuts 1 2 Nylock Cross Member h Install bumper onto two kit brackets rear bumper with six studs and six nuts Kit Bracket gt R Bumper Driver Six Studs amp Six Nuts Rear Bumper I Align bumper to bed according to previously recorded bumper to bed measurements Frontier Kit 40083 j Install lower plastic step onto bumper and 3 Fuel filler A WARNING Use extreme caution when working near the fuel lines bumper crossmember and the fuel tank Clean up spilled fuel immediately A spark could cause an explosion or fire resulting in seri ous personal injury and property damage a Loosen clamp and remove fuel filler hose from fuel filler Lower Plastic Step k TIGHTEN six studs and six nuts Fuel I TIGHTEN six bolts and two kit brackets rear Filler bumper m TIGHTEN eight kit bolts 1 2 x 1 1 2 and two Fuel Filler kit brackets rear bumper support Hose n Install upper plastic step onto bumper b Install kit hose 1 x 3 onto fuel filler with kit clamp 20 hose DO
28. t 2 w stud Bracket 2 Z shaped Bracket 2 1 2 C shaped Bracket 3 w stud Bracket front bumper driver Bracket front bumper passenger Accessories Kit 6423 Front amp Rear Gap Guards Bracket radiator driver Bracket radiator passenger Bracket rear bumper driver Bracket rear bumper passenger Bracket rear bumper support Clamp 10 hose Clamp 20 hose Decal bumper warning Decal logo Decal warning Extension fuel filler Extension shift 5 8 x 3 Extension steering Hose 1 x3 Hose 5 8 x 14 Loctite 6ml bottle Nut 1 2 Nylock Nut 1 4 Nylock Spacer 250 Spacer 2 x 3 x 1 Spacer 2 x 3 x 2 Tie U nut 5 16 Washer 1 2 SAE Washer 1 2 USS Washer 1 4 SAE hm WO OOo pho S Pd NO PO S i A RS 2D UWL HS OCs S _ S Oc Ssd i NY OC OD IN N Copyright 05 06 Depending on the vehicle configuration automatic or Performance Automotive Group manual transmission 2WD or 4WD cab length bed www p a g net length etc some parts may not be used 35 Frontier Kit 40083
29. uring installation of the kit the Supple mental Restraint System SRS or airbag must remain deactivated Do not allow anyone near the airbag dur ing installation Refer to the factory service manual or owner s manual for the recommended procedure to disable the SRS After you install the kit reactivate the SRS before driving the vehicle Performance Automotive Group recommends using the Loctite supplied in the kit on the threads of all kit nuts and bolts unless specified otherwise in these instructions Frontier Kit 40083 Before Starting Installation NOTE Kit parts are prefaced by the word kit and appear in bold print 1 Carefully read all warnings and instructions com pletely before beginning 2 Verify all parts have been received in this kit by checking the parts list at the end of this document lf parts are missing from kit please be prepared to pro vide the following information 1 Name of purchase location 2 Bar Code on side of box 3 Date above bar code 4 Date inside box cover 5 Inspector from inside box cover 3 Only install this kit on the vehicle for which it is specified lf anytime during the installation you encounter something different from what is outlined in the instructions call technical support at 928 636 7080 4 Special tools needed a Welder or access to a professional welding shop b Die grinder or similar tool capable of cutting metal c Saws All or si

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