Nissan 40053 User Manual
3651 N Highway 89 • Chino Valley, AZ 86323
(928) 636-7080
NISSAN TITAN
3” BODY LIFT
INSTALLATION INSTRUCTIONS
2004-2005 KIT # 40053
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 sudden sharp
turns or abrupt maneuvers and always make sure all
vehicle occupants have their seat belts fastened.
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.
CAUTION
Proper installation of this kit requires knowledge of the
factory recommended procedures for removal and
installation of original equipment components. We recommend 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 similar components install this kit.
WARNING
DO NOT combine suspension, body, or other lift
devices. Use of vehicle with combined lifts may result
in unsafe and/or unexpected handling characteristics.
WARNING
This kit should only be installed on a vehicle that is in
good working condition. Before you install the kit, thoroughly 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 recommend 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.
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.
WARNING
The installation of larger tires may reduce the effectiveness of the Braking System.
WARNING
Always wear eye protection when operating power
tools.
WARNING
Before you install this kit, block the vehicle tires to prevent the vehicle from rolling.
WARNING
Accidental deployment of the air bag can result in serious personal injury or death. To avoid accidental
deployment during installation of the kit, the Supplemental Restraint System (SRS, or airbag) must remain
deactivated. Do not allow anyone near the airbag during 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.
NOTE
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.
1 ‘04-’05 Nissan Titan - Kit 40053
Before Starting Installation
Engine Compartment
NOTE
Kit parts are prefaced by the word kit and appear in
bold print.
1. Carefully read all warnings and instructions completely before beginning.
2. Verify all parts have been received in this kit by
checking the parts list at the end of this document.
NOTE
If parts are missing from kit, please be prepared to provide 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. If anytime during the installation you
encounter something different from what is outlined
in the instructions, call technical support at (928)
636-7080.
1. Battery cables
a. Disconnect both battery cables. Disconnect neg-
ative cable first, then positive cable.
Positive
Cable
Battery
Negative
Cable
Measurements
1. Measure and record distance between front bumper
and fenders.
Driver Side _____Passenger Side _____
2. Measure and record distance between rear bumper
and bed.
4. Special tools needed:
a. Die grinder or similar tool capable of cutting
metal
b. Welder or access to a professional welding
shop.
5. Park the vehicle on a clean, dry, flat, level surface
and block the tires so the vehicle cannot roll in either
direction.
Driver Side _____Passenger Side _____
3. Measure and record distance between cab and bed.
Driver Side _____Passenger Side _____
Inside Cab
1. Airbag fuse
NOTE
The location of the airbag fuse may vary; check the
owner's manual.
a. Remove fuse cover.
2 ‘04-’05 Nissan Titan - Kit 40053
b. Remove airbag fuse.
Fuse Cover
Airbag Fuse
WARNING
Accidental deployment of the air bag can result in serious personal injury or death. To avoid accidental
deployment during installation of the lift kit, the Supplemental Restraint System (SRS, or airbag) must remain
deactivated. Do not allow anyone near the airbag during 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.
b. Remove four bolts and skid plate from frame and
vehicle.
Skid Plate
Bolts
Frame
c. If equipped, remove four bolts and two tow
hooks from frame.
Tow Hooks
Frame
Bolts
CAUTION
If the following step is not performed, the airbag clockspring could be damaged. Do not turn the steering
wheel while the steering shaft is disconnected.
c. Strap steering wheel to prevent accidental
movement.
Prepare to Install Kit
Front of vehicle
1. SE & LE models: Front bumper
a. If equipped, remove two wiring harness connec-
tors from running lights.
Wiring
Harness
Connector
Running
Lights
d. Remove four bolts and two side impact braces
from frame.
Side Impact
Braces
Frame
Bolts
e. Remove four nuts and two side impact braces
from front bumper.
Side Impact
Braces
Front
Bumper
Nuts
3 ‘04-’05 Nissan Titan - Kit 40053
f. Remove grill from core support and vehicle by
releasing eight grill turn clips.
Grill Turn Clips
Grill
Top of Grill
g. Remove six bolts and front bumper from front
bumper brackets and vehicle.
2. XE models: Front bumper
a. Remove eight turn clips and grill from vehicle.
Grill Turn Clips
Grill
Top of Grill
b. Remove two screws and three pop-up clips from
front bumper fascia and skid plate.
Bolt
Front
Bumper
Front
Bumper
Bolt
Bumper
Brackets
Pop-Up
Clips
Front
Bumper
Fascia
Screws
c. Remove six screws from driver and passenger
front bumper fascia and wheel wells.
Wheel Well
Screws
Front
Bumper
Fascia
4 ‘04-’05 Nissan Titan - Kit 40053
d. Pull driver and passenger wheel well back and
remove four bolts from front bumper fascia and
front fenders.
g. Remove six bolts, four nuts, and two side
bumper braces from front bumper and side
impact braces.
Wheel Well
Front
Fender
Front
Bumper
Fascia
Bolts
e. Remove six bolts and front bumper fascia from
vehicle.
Core
Support
Bolts
Front
Bumper
Fascia
f. Remove two clips and foam support from front
bumper.
Bolts
Side
Bumper
Braces
Nuts
h. Remove four bolts and two side impact braces
from frame.
Side Impact
Brace
Frame
Bolts
i. Remove four bolts and skid plate from frame and
vehicle.
Skid Plate
Front
Bumper
Foam
Support
Clips
Bolts
Frame
5 ‘04-’05 Nissan Titan - Kit 40053
Engine Compartment
1. Lower radiator
a. Remove hose clip and metal transmission cooler
hose from fan shroud.
b. Remove two clips, hose clamp, and air cleaner
cover from air cleaner base.
Air Cleaner
Cover
Clips
Fan Shroud
Lower Fan
Shroud
Hose Clip,
Metal Trans.
Cooler Hose
b. Remove transmission cooler hose and lower fan
shroud from fan shroud and vehicle.
Lower Fan
Shroud
Trans. Cooler
Hose
Hose
Clamp
Air Cleaner
Base
c. Re move two bolts and intake cover from engine.
d. Remove hose clamp and air intake hose from
engine. Position intake hose to the side.
Intake Cover
Bolts
Air Intake
Hose
Engine
c. Drain cooling system into a clean container
according to manufacturers specifications.
2. Air handling system
a. Remove push clip, wire harness and wire har-
ness connector from air cleaner cover.
Push Clip
Wire
Harness
Connector
Air Cleaner
Cover
Intake Hose
Hose Clamp
e. Remove axle vent hose, and axle vent hose clip
from air cleaner base.
Axle Vent
Hose
Axle Vent
Hose Clip
Air Cleaner
Base
6 ‘04-’05 Nissan Titan - Kit 40053
3. Radiator fan shroud
a. Remove hose clamp and upper radiator hose
from radiator. Zip-tie upper radiator hose to
engine bracket.
d. Remove four nuts and fan clutch assembly from
fan pulley and vehicle. Install nuts on fan pulley.
Hose Clamp
Radiator
Upper Radiator Hose
Zip-tie
b. Remove three hoses from two fan shroud clips.
Hoses
Fan
Shroud Clips
Fan Pulley
Nuts
Fan Clutch
Assembly
4. Radiator
a. Remove two shoulder bolts from radiator and
core support.
Shoulder Bolt
Core Support
Radiator
c. Remove two bolts and fan shroud from radiator.
Lift and remove fan shroud from vehicle.
Bolts
Fan Shroud
Radiator
5. Inner fender well passenger side
a. Remove two clips from wiring harness.
b. Remove AC line from clip on inner fender.
AC Line, Clip
Inner Fender
Clips
Wiring Harness
7 ‘04-’05 Nissan Titan - Kit 40053
c. Remove two bolts and transmission cooler line
brackets from frame.
Bolt, Transmission
Cooler Line Brackets
Frame
7. Inner fender well driver side
a. Remove two bolts and power steering cooler
lines from frame.
Power
Steering
Cooler Lines
d. Remove clip and wiring harness from frame.
Clip,
Wiring Harness
Frame
6. Fire wall
a. Remove nut and AC selector valve from fire wall.
Nut
Fire Wall
AC Selector
Valve
Bolts
Frame
b. Remove clip and wiring harness from frame.
Wiring
Harness
Clip
Frame
Upper
A-arm
8. Steering shaft
a. Mark lower steering shaft and rack and pinion as
shown. Remove bolt and lower steering shaft
from rack and pinion.
Lower Steering Shaft
b. Remove nut and AC line bracket from fire wall.
Nut
Fire Wall
AC Line
Bolt
Mark
Rack & Pinion
8 ‘04-’05 Nissan Titan - Kit 40053
9. Fuel lines at the fire wall
a. Remove two nuts and fuel / brake line bracket,
from fire wall.
Nut
Fuel / Brake
Line Bracket
b. Reposition catalytic converter ground strap on
body so end link connector is pointing forward.
End Link
Connector
Body
Ground Strap
Nut
Frame
1. Side step driver side
a. Remove six bolts and side step from three side
step brackets.
Bolt
Side Step Brackets
3. Side step passenger side
a. Remove six bolts and side step from three side
step brackets.
Bolt
Side Step Brackets
Side Step
4. Frame rail passenger side
Side Step
2. Drive line hoop
a. Remove four bolts and drive line hoop from vehi-
cle.
Bolts
Drive Line Hoop
a. Remove plastic cover from wiring harness
bracket.
Plastic Cover
Wiring Harness Bracket
9 ‘04-’05 Nissan Titan - Kit 40053
b. Remove bolt and wiring harness bracket from
frame.
b. Remove fuel cap from fuel filler. Push fuel filler
rubber gasket and fuel filler toward inside of bed.
Fuel Cap
Fuel Filler
Wiring Harness Bracket
Bolt
Frame
c. Remove two wirin g harness push clips and wir-
ing harness from frame / body mount perch.
Push Clips
Wiring
Harness
Body Mount
Perch
Rear of Vehicle
Rubber
Gasket
2. Spare tire cranking mechanism
a. Lower the spare tire according to the manufac-
turers specifications.
b. Remove three push clips and plastic housing
from frame cross member.
c. Re move two bolts and spare tire winch mecha-
nism from frame cross member.
Plastic Housing
Push Clips
1. Fuel filler
WARNING
Use extreme caution when working near fuel lines and
fuel tank. Clean up spilled fuel immediately. A spark
could cause an explosion or fire resulting in serious
personal injury and property damage.
a. Remove bolt and fuel filler bracket from bed.
Fuel Filler
Bracket
Bolt
Bed
Cross
Member
Bolts
Winch
Mechanism
3. Rear bumper wiring driver side
a. Remove wiring harness and clip from bumper.
Wiring Harness & Clip
Bumper
10 ‘04-’05 Nissan Titan - Kit 40053
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