The Vehicle: 2007 Nissan Frontier 4.0L VQ40DE V6 6MT.
The Problem:
A severe "hard miss" and hesitation under moderate acceleration/load and a rough idle. It originally threw a P0300 (Random Misfire) with crazy fuel trims (Bank 2 dumping/pulling fuel), but we’ve finally isolated the physical miss to Cylinder 6. The miss is intermittent but recurrent.
The Insane Part:
This exact same fault existed on the original engine, which has since been replaced with a reman engine. The misfire on Cylinder 6 immediately continued on the replacement engine.
Thinking it was the computer, I swapped the ECU with a known-good/programmed unit. Zero effect.
What We Have Tested/Confirmed:
-Compression: Passes perfectly.
-Leak Down: Passes perfectly.
-Spark: Present and visually confirmed.
-Injector: Injector is new. The mechanic even ran temporary bypass wires directly from the ECU to the Cylinder 6 injector to 100% rule out a hidden break or short in the factory harness. The misfire remained exactly the same.
Parts Replaced (All with no effect):
-Entire Engine Assembly long block
-ECU / ECM
-Spark Plugs & Ignition Coils (NGK)
-Fuel Injectors (BOSCH)
-Catalytic Converters (Currently 1,000 miles on them. We even tested with gutted cats to rule out backpressure—no change).
-MAF Sensor (Tested with a known-good OEM unit).
Things We Have Already Ruled Out:
-Flywheel Indexing / Reluctor Ring: Mechanic just put an oscilloscope on the Crankshaft Position Sensor. The waveform is perfectly clean. We visually inspected the reluctor ring teeth, and they are pristine.
-O2 Sensor Wiring: We did end-to-end continuity testing from the Bank 2 AF sensor plugs all the way to the ECM pins. No shorts to ground, no cross-continuity. (Note: I had a scan tool glitch showing a "ghost" 0.89V on Bank 2 even when unplugged, but the ECU swap proved this was just a default placeholder value on my scanner, not a real electrical short).
-EVAP Purge Valve: Tested good (not stuck open).
Current Status:
The truck has a mechanically sound engine, a good ECU, spark on Cyl 6, a direct hardwired fuel pulse to Cyl 6, and perfect compression. Yet, Cylinder 6 is dead/missing under load and intermittent missing at idle, causing the ECM to go crazy with fuel trims on Bank 2.
My mechanic is out of ideas. I am out of ideas. Since the engine and ECU are both different, the only things remaining from the original truck are the chassis, the fuel pump/tank, sensors, and the rest of the main wiring harness.
Has anyone ever seen a chassis-side or harness-side issue cause a single-cylinder misfire under load that survives an engine swap?
Any out-of-the-box theories are welcome. I'm losing my mind.