ENGINE LUBRICATION &

COOLING SYSTEMS GI

SECTION LC MA

EM

EC

CONTENTS FE

QG COMPONENTS .......................................................18
CL
CONTROL SYSTEM ................................................18
ENGINE LUBRICATION SYSTEM..................................3 Changing Engine Coolant..........................................18
Precautions ..................................................................3 MT
- DRAINING ENGINE COOLANT - ............................18
LIQUID GASKET APPLICATION PROCEDURE ............3 - REFILLING ENGINE COOLANT - ...........................19
Preparation ..................................................................3 - FLUSHING COOLING SYSTEM -............................20
SPECIAL SERVICE TOOLS ........................................3
AT
Radiator (Aluminum type)..........................................21
Lubrication Circuit ........................................................4 PREPARATION .......................................................21
Oil Pressure Check......................................................5 DISASSEMBLY ........................................................21 AX
Oil Pump ......................................................................5 ASSEMBLY .............................................................22
REMOVAL AND INSTALLATION .................................5 INSPECTION ...........................................................23
DISASSEMBLY AND ASSEMBLY................................6 Overheating Cause Analysis .....................................24 SU
INSPECTION .............................................................7 Service Data and Specifications (SDS).....................25
REGULATOR VALVE INSPECTION ............................8 THERMOSTAT ........................................................25
Changing Engine Oil....................................................8 RADIATOR ..............................................................25 BR
Changing Oil Filter.......................................................9 COOLANT CAPACITY ..............................................25
Service Data and Specifications (SDS).....................10
OIL PRESSURE CHECK ..........................................10 YD
ST
OIL PUMP INSPECTION ..........................................10
REGULATOR VALVE INSPECTION ..........................10 ENGINE LUBRICATION SYSTEM................................26
OIL CAPACITY ........................................................10 Precautions ................................................................26 RS
ENGINE COOLING SYSTEM........................................11 LIQUID GASKET APPLICATION PROCEDURE ..........26
Precautions ................................................................11 Preparation ................................................................26
SPECIAL SERVICE TOOLS ......................................26
BT
LIQUID GASKET APPLICATION PROCEDURE ..........11
Preparation ................................................................11 Lubrication Circuit ......................................................27
SPECIAL SERVICE TOOLS ......................................11 Oil Pressure Check....................................................29 HA
Cooling Circuit ...........................................................12 Oil Pump ....................................................................30
System Check............................................................12 REMOVAL AND INSTALLATION ...............................30
CHECKING COOLING SYSTEM HOSES ...................12 DISASSEMBLY AND ASSEMBLY..............................30 SC
CHECKING RADIATOR ............................................13 OIL PUMP INSPECTION ..........................................30
CHECKING RADIATOR CAP ....................................13 REGULATOR VALVE INSPECTION ..........................31
CHECKING COOLING SYSTEM FOR LEAKS ............14 Changing Engine Oil..................................................32 EL
Water Pump ...............................................................14 Oil Filter Bracket ........................................................33
REMOVAL AND INSTALLATION ...............................14 REMOVAL AND INSTALLATION ...............................33
INSPECTION ...........................................................15 Changing Oil Filter.....................................................33 IDX
Thermostat.................................................................15 REMOVAL ...............................................................34
REMOVAL AND INSTALLATION ...............................15 INSTALLATION........................................................34
INSPECTION ...........................................................16 Oil Cooler...................................................................35
Radiator .....................................................................17 REMOVAL AND INSTALLATION ...............................35
COMPONENTS .......................................................17 Service Data and Specifications (SDS).....................36
Cooling Fan ...............................................................18 OIL PRESSURE CHECK ..........................................36
 CONTENTS (Cont’d)
REGULATOR VALVE INSPECTION ..........................36 REMOVAL AND INSTALLATION ...............................43
OIL PUMP INSPECTION ..........................................36 INSPECTION ...........................................................45
ENGINE OIL CAPACITY ...........................................36 Radiator .....................................................................45
ENGINE COOLING SYSTEM........................................37 COMPONENTS .......................................................45
Precautions ................................................................37 REMOVAL AND INSTALLATION ...............................46
LIQUID GASKET APPLICATION PROCEDURE ..........37 Cooling Fan ...............................................................46
Preparation ................................................................37 COMPONENTS .......................................................46
SPECIAL SERVICE TOOLS ......................................37 CONTROL SYSTEM ................................................46
Cooling Circuit ...........................................................38 Changing Engine Coolant..........................................47
System Check............................................................40 - DRAINING ENGINE COOLANT - ............................47
CHECKING COOLING SYSTEM HOSES ...................40 - REFILLING ENGINE COOLANT - ...........................48
CHECKING RADIATOR ............................................40 - FLUSHING COOLING SYSTEM -............................49
CHECKING RADIATOR CAP ....................................40 Radiator (Aluminum type)..........................................50
CHECKING COOLING SYSTEM FOR LEAKS ............41 Overheating Cause Analysis .....................................50
Water Pump ...............................................................42 Service Data and Specifications (SDS).....................51
REMOVAL AND INSTALLATION ...............................42 THERMOSTAT ........................................................51
REMOVAL ...............................................................42 RADIATOR ..............................................................51
INSPECTION ...........................................................43 ENGINE COOLANT CAPACITY ................................51
INSTALLATION........................................................43
Thermostat.................................................................43

LC-2
 ENGINE LUBRICATION SYSTEM QG
Precautions

Precautions
LIQUID GASKET APPLICATION PROCEDURE
1. Use a scraper to remove all traces of old liquid gasket from
NJLC0001
GI
mating surfaces and grooves. Also, completely clean any oil
from these areas. MA
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
I For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm EM
(0.138 to 0.177 in).
I For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
EC
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant. FE

CL

AEM080
MT
Preparation
SPECIAL SERVICE TOOLS AT
NJLC0002

Tool number
Description AX
Tool name

ST25051001 Measuring oil pressure

Oil pressure gauge Maximam measuring rang
2,452 kPa (24.5 bar, 25 kg/cm2, 356 psi)
SU

BR
NT050

ST25052000 Adapting oil pressure gauge to cylinder block

Hose ST

RS

NT559
BT
KV10115801 Removing oil filter
Oil filter wrench HA

SC
NT772

WS39930000 Pressing the tube of liquid gasket EL

Tube presser

IDX
NT052

LC-3
 ENGINE LUBRICATION SYSTEM QG
Lubrication Circuit

Lubrication Circuit NJLC0003

SEM852FB

SLC339BB

LC-4
ENGINE LUBRICATION SYSTEM QG
Oil Pressure Check

Oil Pressure Check NJLC0004

WARNING:
I Be careful not to burn yourself, as the engine and oil may GI
be hot.
I For M/T models, put gearshift lever in Neutral “N” posi-
tion. For A/T models, put selector lever in Park “P” posi-
MA
tion.
1. Check oil level. EM
2. Remove oil pressure switch.

SEM853F

3. Install pressure gauge.

4. Start engine and warm it up to normal operating temperature.
EC
5. Check oil pressure with engine running under no-load.
For Sedan
FE
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi)

Idle speed More than 69 (0.69, 0.7, 10) CL

2,000 More than 284 (2.84, 2.9, 41)

SLC926-A 6,000 More than 422 (4.22, 4.3, 61) MT

For Hatchback AT
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi) AX
Idle speed More than 98 (0.98, 1.0, 14)

2,000 More than 294 (2.94, 3.0, 43) SU

6,000 More than 392 (3.92, 4.0, 57)

I If difference is extreme, check oil passage and oil pump

BR
for oil leaks.
6. After the inspections, install the oil pressure switch as follows. ST
a. Remove the old sealant adhering to the switch and engine.
b. Apply Genuine Liquid Gasket or equivalent to the thread and
tighten. RS
: 13 - 17 N·m (1.25 - 1.75 kg-m, 9 - 12 ft-lb)
BT

HA

Oil Pump SC
REMOVAL AND INSTALLATION NJLC0005
I Make sure that O-ring is fitted properly. EL
1. Drain engine oil.
2. Remove drive belts. Refer to EM-22, “DRIVE BELTS”.
3. Remove oil pan. Refer to EM-26, “OIL PAN”. IDX
4. Remove oil strainer.
5. Remove front cover. Refer to EM-29, “TIMING CHAIN”.
6. Install front cover.
7. Reinstall parts in reverse order of removal.
LC-5
 ENGINE LUBRICATION SYSTEM QG
Oil Pump (Cont’d)
DISASSEMBLY AND ASSEMBLY NJLC0006

SEM854FA

1. Oil pump cover 5. Gasket 8. Spring

2. Inner rotor 6. Oil strainer 9. Washer
3. Outer rotor 7. Regulator valve 10. Plug
4. Front cover

I When installing oil pump, apply engine oil to rotors.

I Install the inner rotor and outer rotor with the punched
marks on the oil pump cover side.

JLC307B

LC-6
ENGINE LUBRICATION SYSTEM QG
Oil Pump (Cont’d)
INSPECTION NJLC0007
Using a feeler gauge, check the following clearances.
Standard clearance: GI
For Sedan
Unit: mm (in)
MA
Body to outer rotor radial clearance 1 0.114 - 0.200 (0.0045 - 0.0079)

Inner rotor to outer rotor tip clearance

2
Below 0.18 (0.0071) EM
Body to inner rotor clearance 3 0.030 - 0.070 (0.0012 - 0.0028)
SEM855F
Body to outer rotor axial clearance 4 0.030 - 0.090 (0.0012 - 0.0035)

Inner rotor to brazed portion of hous-

0.045 - 0.091 (0.0018 - 0.0036)
ing clearance 5 EC

For Hatchback FE
Unit: mm (in)

Body to outer rotor radial clearance 1 0.250 - 0.325 (0.0098 - 0.0128)

CL
Inner rotor to outer rotor tip clearance
Below 0.18 (0.0071)
2
SEM856F Body to inner rotor clearance 3 0.030 - 0.085 (0.0012 - 0.0033)
MT
Body to outer rotor axial clearance 4 0.030 - 0.090 (0.0012 - 0.0035)
AT
Inner rotor to brazed portion of hous-
0.045 - 0.091 (0.0018 - 0.0036)
ing clearance 5
AX

SU

BR
I If the tip clearance (2) exceeds the limit, replace rotor set.
I If body to rotor clearances (1, 3, 4, 5) exceed the limit,
ST
replace front cover assembly.
RS

BT

HA

SC

EL

IDX

SEM857FA

LC-7
 ENGINE LUBRICATION SYSTEM QG
Oil Pump (Cont’d)
REGULATOR VALVE INSPECTION NJLC0008
1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil.
Check that it falls smoothly into the valve hole by its own
weight.
If damaged, replace regulator valve set or front cover assem-
bly.

SLC986AA

4. Check regulator valve to front cover clearance.

Clearance 6:
For Sedan
0.040 - 0.097 mm (0.0016 - 0.0038 in)
For Hatchback
0.052 - 0.088 mm (0.0020 - 0.0035 in)
If it exceeds the limit, replace front cover assembly.

SLC101B

Changing Engine Oil NJLC0035

WARNING:
I Be careful not to burn yourself, as the engine oil is hot.
I Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine com-
ponents.
2. Stop engine and wait more than 10 minutes.
SMA915C 3. Remove drain plug and oil filler cap.
4. Drain oil and refill with new engine oil.
Oil specification and viscosity (Except for Europe):
I API grade SE, SF, SG, SH or SJ
I ILSAC grade GF-I & GF-II
Oil specification and viscosity (For Europe):
I API grade SG, SH or SJ
I ILSAC grade GF-I & GF-II
Refer to MA-21, “RECOMMENDED FLUIDS AND LUBRI-
CANTS”.
SMA390C Refill oil capacity (Approximate):
Unit:  (Imp qt)

With oil filter change 2.7 (2-3/8)

Drain and refill
Without oil filter change 2.5 (2-1/4)

Dry engine (engine overhaul) 3.1 (2-3/4)

CAUTION:
I Be sure to clean drain plug and install with new washer.
Drain plug:
: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)

LC-8
ENGINE LUBRICATION SYSTEM QG
Changing Engine Oil (Cont’d)
I The refill capacity changes depending on the oil tempera-
ture and drain time, use these values as a reference and
be certain to check with the dipstick when changing the GI
oil.
5. Check oil level.
6. Start engine and check area around drain plug and oil filter for MA
oil leakage.
7. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
EM

Changing Oil Filter NJLC0010

The oil filter is a small, full-flow cartridge type and is provided with EC
a relief valve.
I Use Tool KV10115801 for removing oil filter.
FE

CL

ALC094
MT
1. Remove oil filter with Tool.
WARNING: AT
Be careful not to burn yourself, as the engine and the engine
oil are hot.
AX

SU

BR
SLC275B

2. Clean oil filter mounting surface on cylinder block. Coat rubber

seal of new oil filter with engine oil. ST

RS

BT

HA
SMA010

3. Screw in the oil filter until a slight resistance is felt, then tighten SC
an additional 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil. EL
I Clean excess oil from engine.
IDX

SMA229B

LC-9
 ENGINE LUBRICATION SYSTEM QG
Service Data and Specifications (SDS)

Service Data and Specifications (SDS)

OIL PRESSURE CHECK NJLC0011

Approximate discharge pressure

Engine speed kPa (bar, kg/cm2, psi)
rpm
Sedan Hatchback

Idle speed More than 69 (0.69, 0.7, 10) More than 98 (0.98, 1.0, 14)

2,000 More than 284 (2.84, 2.9, 41) More than 294 (2.94, 3.0, 43)

6,000 More than 422 (4.22, 4.3, 61) More than 392 (3.92, 4.0, 57)

OIL PUMP INSPECTION NJLC0013

Unit: mm (in)

Model Sedan Hatchback

Body to outer rotor radial clearance 0.114 - 0.200 (0.0045 - 0.0079) 0.250 - 0.325 (0.0098 - 0.0128)

Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)

Body to inner rotor clearance 0.030 - 0.070 (0.0012 - 0.0028) 0.030 - 0.085 (0.0012 - 0.0033)

Body to outer rotor axial clearance 0.030 - 0.090 (0.0012 - 0.0035)

Inner rotor to brazed portion of housing clear-

0.045 - 0.091 (0.0018 - 0.0036)
ance

REGULATOR VALVE INSPECTION NJLC0012

Unit: mm (in)

Model Sedan Hatchback

Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0382) 0.052 - 0.088 (0.0020 - 0.0035)

OIL CAPACITY NJLC0036

Unit:  (Imp qt)

With oil filter change 2.7 (2-3/8)

Without oil filter change 2.5 (2-1/4)

Dry engine (engine overhaul) 3.1 (2-3/4)

LC-10
 ENGINE COOLING SYSTEM QG
Precautions

Precautions
LIQUID GASKET APPLICATION PROCEDURE
1. Use a scraper to remove all traces of old liquid gasket from
NJLC0014
GI
mating surfaces and grooves. Also, completely clean any oil
from these areas. MA
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
I For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm EM
(0.138 to 0.177 in).
I For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
EC
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant. FE

CL

AEM080
MT
Preparation
SPECIAL SERVICE TOOLS AT
NJLC0015

Tool number
Description AX
Tool name

WS39930000 Pressing the tube of liquid gasket

Tube presser
SU

BR
NT052

EG17650301 Adapting radiator cap tester to radiator filler neck

Radiator cap tester a: 28 (1.10) dia. ST
adapter b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in) RS

NT564
BT
KV99103510 Installing radiator upper and lower tanks
Radiator plate pliers A
HA
NT224

KV99103520 Removing radiator upper and lower tanks SC

Radiator plate pliers B

NT225
EL

IDX

LC-11
 ENGINE COOLING SYSTEM QG
Cooling Circuit

Cooling Circuit NJLC0016

SLC535B

System Check NJLC0017

WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure fluid escaping from the
radiator.
Wrap a thick cloth around the cap. Slowly turn it a quarter turn
to allow built-up pressure to escape. Carefully remove the cap
by turning it all the way.
CHECKING COOLING SYSTEM HOSES NJLC0017S01
Check hoses for the following:
I Improper attachment
I Leaks
I Cracks
I Damage
I Loose connections
I Chafing
I Deterioration

LC-12
 ENGINE COOLING SYSTEM QG
System Check (Cont’d)
CHECKING RADIATOR NJLC0017S04
Check radiator for mud or clogging. If necessary, clean radiator as
follows. GI
I Be careful not to bend or damage the radiator fins.
I When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, rediator shroud and horns.
MA
Then tape the harness and connectors to prevent water from
entering. EM
1. Apply water by hose to the back side of the radiator core ver-
tically download.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor. EC
4. Blow air into the back side of radiator core vertically download.
I Use compressesd air lower than 490 kPa (4.9 bar, 5 kg/cm2, FE
71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out. CL

MT
CHECKING RADIATOR CAP NJLC0017S03
To check radiator cap, apply pressure to cap with a tester. AT
Radiator cap relief pressure:
Standard
AX
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit SU
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
BR
SLC613-A

Pull the negative pressure valve to open it.

Check that it closes completely when released. ST
I Check the radiator cap negative pressure valve for contamina-
tion or damage to the valve seat.
RS
I Move the negative pressure valve to check for abnormalities to
the opening/shutting operation.
CAUTION: BT
I Be sure to perform the inspections after cooling down the
engine.
I Before connecting the radiator cap to the tester, apply HA
SMA967B engine coolant to the cap sealing.
I Replace the radiator cap if abnormalities are found with the
negative pressure valve, or if the valve opening pressure is out
SC
of the standard range.
EL

IDX

LC-13
 ENGINE COOLING SYSTEM QG
System Check (Cont’d)
CHECKING COOLING SYSTEM FOR LEAKS NJLC0017S02
To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
I Higher pressure than specified may cause radiator dam-
age.
I Be sure to perform the inspections after cooling down the
engine.
SLC756AA
I Use a hose adapter between the cap tester and filler neck
to prevent the radiator filler neck from deforming.
I If any abnormalities are found, repair or replace the malfunc-
tioning parts.

Water Pump
REMOVAL AND INSTALLATION NJLC0018

SEM858F

CAUTION:
I When removing water pump assembly, be careful not to
get engine coolant on drive belt.
I Water pump cannot be disassembled and should be
replaced as a unit.
1. Drain engine coolant.
Refer to LC-18, “Changing Engine Coolant”.
2. Remove drive belts and idler pulley.
3. Loosen water pump pulley bolts.
4. Remove water pump pulley.
SEM859F 5. Remove front right wheel.
LC-14
 ENGINE COOLING SYSTEM QG
Water Pump (Cont’d)
6. Remove front right undercover and front right fender protector.
7. Remove water pump bolts.
8. Remove water pump. GI
9. Reinstall parts in reverse order of removal.
MA

EM

INSPECTION NJLC0019
I Check body assembly and vane for rust or corrosion. EC
I Check for rough operation due to excessive end play.
I After installing water pump, and check for leaks using radiator
cap tester. FE

CL

SEM860F
MT
Thermostat
REMOVAL AND INSTALLATION AT
NJLC0021

AX

SU

BR

ST

RS

BT

SEM861F
HA

Be careful not to spill engine coolant over engine compart- SC

ment. Use a rag to absorb engine coolant.
1. Drain engine coolant.
Refer to LC-18, “Changing Engine Coolant”. EL
2. Remove water inlet, then take out thermostat.

IDX

LC-15
 ENGINE COOLING SYSTEM QG
Thermostat (Cont’d)
3. Install gum ring to thermostat.

SEM862F

4. Install thermostat with jiggle valve or air bleeder at upper side.

After installation, run engine for a few minutes, and check
for leaks.

SEM863F

INSPECTION NJLC0022
1. Check for valve seating condition at normal room temperature.
It should seat tightly.
2. Check valve opening temperature and valve lift.
Valve opening temperature °C (°F) 80 - 84 (176 - 183)

Valve lift mm/°C (in/°F) More than 8/95 (0.31/203)

3. Then check if valve closes at 5°C (9°F) below valve opening

temperature.
SLC343

LC-16
 ENGINE COOLING SYSTEM QG
Radiator

Radiator
COMPONENTS =NJLC0025
GI

MA

EM

EC

FE

CL

MT

AT

AX
SLC279B
SU
1. Reservoir tank 5. Mounting bracket 9. Lower radiator hose
2. Reservoir tank bracket 6. Radiator 10. Oil cooler hose (A/T models)
3. Reservoir hose 7. Radiator drain plug (For Sedan) 11. Upper radiator hose BR
4. Radiator cap 8. Mounting rubber 12. Cooling fan assembly

ST

RS

BT

HA

SC

EL

IDX

LC-17
 ENGINE COOLING SYSTEM QG
Cooling Fan

Cooling Fan NJLC0026

COMPONENTS NJLC0026S01

JLC314B

CONTROL SYSTEM NJLC0026S02

Cooling fans are controlled by the ECM. For details, refer to EC-950,
TROUBLE DIAGNOSIS FOR OVERHEAT (COOLING SYSTEM).

Changing Engine Coolant NJLC0037

WARNING:
To avoid the danger of being scalded, never change the engine
coolant when the engine is hot.
Wrap a thick cloth around cap and carefully remove the cap.
First turn the cap a quarter of a turn to release built-up pres-
sure. Then turn the cap all the way.
— DRAINING ENGINE COOLANT — NJLC0037S01
1. Set air conditioning system as follows to prevent engine cool-
ant from remaining in the system.
SLC276BB

LC-18
 ENGINE COOLING SYSTEM QG
Changing Engine Coolant (Cont’d)
a. Turn ignition switch ON and set temperature controller to maxi-
mum hot position.
b. Wait 10 seconds before turning ignition switch OFF. GI

MA

EM

2. Open radiator drain plug at the bottom of radiator or remove

lower radiator hose, and remove radiator filler cap to drain
engine coolant. EC
3. Remove reservoir tank, drain engine coolant, then clean res-
ervoir tank.
FE
I Be careful not to allow engine coolant to contact drive
belts.
4. Cover the exhaust tube heat shield to prevent from splashing CL
engine coolant.

SMA033D
MT
5. Remove drain plug on cylinder block and air relief plug.
6. Check drained engine coolant for contaminants such as rust, AT
corrosion or discoloration. If contaminated flush engine cooling
system, refer to LC-20, “FLUSHING COOLING SYSTEM”.
7. Blow the engine coolant around the exhaust tube heat shield. AX

SU

BR
SLC277B

ST

RS

BT

HA
SLC278B

— REFILLING ENGINE COOLANT — NJLC0037S02

SC
1. Install reservoir tank, radiator drain plug or lower radiator hose
and cylinder block drain plug.
I Apply sealant to the thread of cylinder block drain plug. EL
: 35 - 44 N·m (3.50 - 4.50 kg-m, 26 - 32 ft-lb)
2. Fill radiator slowly with engine coolant until engine coolant IDX
spills from the air relief plug, then install air relief plug.
Air relief plug:
: 6.7 - 7.8 N·m (0.68 - 0.80 kg-m, 59 - 69 in-lb)
I Use genuine NISSAN anti-freeze coolant or equivalent
mixed with water (distilled or demineralized).
LC-19
 ENGINE COOLING SYSTEM QG
Changing Engine Coolant (Cont’d)
Refer to MA-21, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Engine coolant capacity (With reservoir tank):
Unit:  (Imp qt)

M/T 6.7 (5-7/8)

For Sedan 6.6 (5-7/8)

A/T
For Hatchback 6.7 (5-7/8)

Reservoir tank engine coolant capacity:

0.7  (5/8 Imp qt)
SMA182B I Pour engine coolant through engine coolant filler neck
slowly to allow air in system to escape.
3. Fill radiator and reservoir tank to specified level.
4. Warm up engine to normal operating temperature without
radiator cap installed.
I If engine coolant overflows radiator filler hole, install filler
cap.
5. Run engine at 2,500 rpm for 10 seconds and return to idle
speed with radiator cap installed.
I Repeat two or three times.
Watch engine coolant temperature gauge so as not to over-
SMA412B heat the engine.
6. Stop engine and cool it down.
I Cool down using a fan to reduce the time.
I If necessary, refill radiator up to filler neck with engine coolant.
7. Refill reservoir tank to MAX level line with engine coolant.
8. Repeat steps 4 through 7 two or more times with radiator cap
installed until engine coolant level no longer drops.
9. Check cooling system for leaks with engine running.
10. Warm up engine, and check for sound of engine coolant flow
while running engine from idle up to 3,000 rpm with heater
temperature controller set at several positions between COOL
and HOT.
I Sound may be noticeable at heater water cock.
11. If sound is heard, bleed air from cooling system by repeating
steps 4 through 7 until engine coolant level no longer drops
I Clean excess engine coolant from engine.
— FLUSHING COOLING SYSTEM — NJLC0037S03
1. Open air relief plug.
2. Fill radiator with water until water spills from the air relief hole,
then close air relief plug. Fill radiator and reservoir tank with
water and reinstall radiator cap.
3. Run engine and warm it up to normal operating temperature.
4. Rev engine two or three times under no-load.
5. Stop engine and wait until it cools down.
6. Drain water.
7. Repeat steps 1 through 6 until clear water begins to drain from
radiator.

LC-20
 ENGINE COOLING SYSTEM QG
Radiator (Aluminum type)

Radiator (Aluminum type) NJLC0081

PREPARATION NJLC0081S01
GI

MA

EM

EC

FE

CL

SLC882AB
MT
1. Attach the spacer to the tip of the radiator plate pliers A.
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in) AT
wide x 8.5 mm (0.335 in) long.
2. Make sure that when radiator plate pliers A are closed dimen-
sion H′′ is approx. 7.6 mm (0.299 in). AX
3. Adjust dimension H′′ with the spacer, if necessary.
SU

BR
SLC655C

DISASSEMBLY
1. Remove upper and lower tanks with Tool.
NJLC0081S02 ST

RS

BT

HA
SLC903

I Grip the crimped edge and bend it upwards so that Tool slips SC
off.
Do not bend excessively.
EL

IDX

SLC893

LC-21
 ENGINE COOLING SYSTEM QG
Radiator (Aluminum type) (Cont’d)
I In areas where Tool cannot be used, use a screwdriver to bend
the edge up.
Be careful not to damage tank.
2. Remove sealing rubbers.

SLC930

3. Make sure the edge stands straight up.

4. Remove oil cooler from tank. (A/T model only)

SLC931

ASSEMBLY NJLC0081S03
1. Install oil cooler. (A/T model only)
Pay attention to direction of conical washer.

SLC894

2. Clean contact portion of tank.

SLC932

3. Install sealing rubber.

Push it in with fingers.
Be careful not to twist sealing rubber.

SLC917A

LC-22
 ENGINE COOLING SYSTEM QG
Radiator (Aluminum type) (Cont’d)
4. Caulk tank in specified sequence with Tool.

GI

MA

EM

SLC904

EC

FE

CL

SLC896 MT
I Use pliers in the locations where Tool cannot be used.
AT

AX

SU

BR
SLC897

5. Make sure that the rim is completely crimped down.

Standard height “H”:
ST
8.0 - 8.4 mm (0.315 - 0.331 in)
6. Confirm that there is no leakage. RS
Refer to Inspection.
BT

HA
SLC554A

INSPECTION NJLC0081S04
SC
1. Apply pressure with Tool.
Specified pressure value:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
EL
WARNING:
To prevent the risk of the hose coming undone while under IDX
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler to seal its inlet and outlet. (A/T
model only)

SLC933

LC-23
 ENGINE COOLING SYSTEM QG
Radiator (Aluminum type) (Cont’d)
2. Check for leakage by soaking radiator in water container.

SLC934

Overheating Cause Analysis NJLC0028

Symptom Check items

Water pump malfunction Worn or loose drive belt

Thermostat stuck closed —

Dust contamination or
Poor heat transfer Damaged fins paper clogging —

Mechanical damage

Clogged radiator cooling Excess foreign material

tube (rust, dirt, sand, etc.)

Cooling fan does not oper-

ate

Reduced air flow High resistance to fan rota- Fan assembly —

tion

Damaged fan blades

Damaged radiator shroud — — —

Improper engine coolant

— — —
Cooling sys- mixture ratio
tem parts
malfunction Poor engine coolant quality — Engine coolant viscosity —

Loose clamp
Cooling hose
Cracked hose

Water pump Poor sealing

Loose
Radiator cap
Poor sealing
Engine coolant leaks
O-ring for damage, deterio-
Insufficient coolant ration or improper fitting
Radiator
Cracked radiator tank

Cracked radiator core

Reservoir tank Cracked reservoir tank

Cylinder head deterioration

Exhaust gas leaks into
Overflowing reservoir tank Cylinder head gasket dete-
cooling system
rioration

LC-24
 ENGINE COOLING SYSTEM QG
Overheating Cause Analysis (Cont’d)

Symptom Check items

High engine rpm under no GI

load

Driving in low gear for

Abusive driving
extended time MA
Driving at extremely high
speed EM
— Overload on engine
Powertrain system malfunc-
tion

Installed improper size

Except cool- wheels and tires —
ing system EC
parts mal- Dragging brakes
function
Improper ignition timing
FE
Blocked bumper —

Installed car brassiere

Blocked radiator grille
CL
Mud contamination or
Blocked or restricted air paper clogging —
flow
Blocked radiator — MT
Blocked condenser
Blocked air flow
Installed large fog lamp
AT

Service Data and Specifications (SDS) AX

THERMOSTAT NJLC0029

Valve opening temperature °C (°F) 80 - 84 (176 - 183) SU

Valve lift mm/°C (in/°F) More than 8/95 (0.31/203)

RADIATOR BR
NJLC0030
2
Unit: kPa (bar, kg/cm , psi)

Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14) ST

Cap reliefpressure
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)

Leakage test pressure 157 (1.57, 1.6, 23) RS

COOLANT CAPACITY NJLC0038
Unit:  (Imp qt) BT
M/T* 6.7 (5-7/8)

Sedan 6.6 (5-7/8) HA

A/T*
Hatchback 6.7 (5-7/8)

Reservoir tank 0.7 (5/8) SC

*: With reservoir tank
EL

IDX

LC-25
 ENGINE LUBRICATION SYSTEM YD
Precautions

Precautions
LIQUID GASKET APPLICATION PROCEDURE NJLC0039
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
I For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
I For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.

AEM080

Preparation
SPECIAL SERVICE TOOLS NJLC0040

Tool number
Description
Tool name

ST25051001 Measuring oil pressure

Oil pressure gauge Maximum measuring rang:
2,452 kPa (24.5 bar, 25 kg/cm2, 356 psi)

NT050

ST25052000 Adapting oil pressure gauge to upper oil pan

Hose

NT559

WS39930000 Pressing the tube of liquid gasket

Tube pressure

NT052

LC-26
ENGINE LUBRICATION SYSTEM YD
Lubrication Circuit

Lubrication Circuit NJLC0041

GI

MA

EM

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

JLC540B

LC-27
 ENGINE LUBRICATION SYSTEM YD
Lubrication Circuit (Cont’d)

JLC539B

LC-28
ENGINE LUBRICATION SYSTEM YD
Oil Pressure Check

Oil Pressure Check NJLC0042

WARNING:
I Be careful not to burn yourself, as the engine and oil may GI
be hot.
I Oil pressure check should be done in “Neutral position”.
MA
1. Check oil level.
2. Remove exhaust front tube.
3. Remove oil pressure switch. EM
4. Install pressure gauge.
SLC283B
5. Install exhaust front tube.
6. Start engine and warm it up to normal operating temperature.
7. Check oil pressure with engine running under no-load.
Except for Europe EC
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi) FE
Idle speed More than 98 (0.98, 1.0, 14)

2,000 More than 265 (2.65, 2.7, 38) CL

4,000 More than 402 (4.02, 4.1, 58)

JLC284B
MT
For Europe
Engine speed Approximate discharge pressure AT
rpm kPa (bar, kg/cm2, psi)

Idle speed More than 140 (1.40, 1.43, 20.3)

AX
2,000 More than 270 (2.69, 2.75, 39.1)

4,000 More than 430 (4.29, 4.38, 62.3) SU

If difference is extreme, check oil passage and oil pump
for oil leaks. BR
SLC926-A 8. After the inspections, install the oil pressure switch as follows.
a. Remove the old sealant adhering to the switch and engine.
b. Apply Genuine Liquid Gasket or equivalent to the thread and ST
tighten.
: 13 - 17 N·m (1.25 - 1.75 kg-m, 9 - 12 ft-lb) RS

BT

HA

SC

EL

IDX

LC-29
 ENGINE LUBRICATION SYSTEM YD
Oil Pump

Oil Pump
REMOVAL AND INSTALLATION =NJLC0043
I When installing oil pump, apply engine oil to rotors.
Refer to EM-108, “Primary Timing Chain” for removal.
Reinstall all parts in the reverse order of removal.
DISASSEMBLY AND ASSEMBLY NJLC0044

JLC285B

OIL PUMP INSPECTION NJLC0045

I Install the inner rotor and outer rotor with the punched
marks on the pump cover side.
Using a feeler gauge, straightedge and micrometers, check the
following clearances:
Unit: mm (in)

Body to outer rotor radial clearance 1 0.114 - 0.260 (0.0045 - 0.0102)

Inner rotor to outer rotor tip clearance

Below 0.18 (0.0071)
2
JLC286B Body to inner rotor axial clearance 3 0.050 - 0.090 (0.0020 - 0.0035)

Body to outer rotor axial clearance 4 0.030 - 0.190 (0.0012 - 0.0075)

Inner rotor to brazed portion of hous-

0.045 - 0.091 (0.0018 - 0.0036)
ing clearance 5

I If the tip clearance (2) exceeds the limit, replace rotor set.
I If body to rotor clearances (1, 3, 4, 5) exceed the limit,
replace oil pump body assembly.

JLC355B

LC-30
ENGINE LUBRICATION SYSTEM YD
Oil Pump (Cont’d)

GI

MA

EM

JLC356B

EC

FE

CL

JLC338B
MT
REGULATOR VALVE INSPECTION NJLC0046
1. Visually inspect components for wear and damage. AT
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil. Check that it falls
AX
smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump body. SU

BR
4. Check regulator valve to oil pump body clearance.
Clearance 6:
ST
6 : 0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the limit, replace oil pump body. RS

BT

HA
JLC358B

SC

EL

IDX

LC-31
 ENGINE LUBRICATION SYSTEM YD
Changing Engine Oil

Changing Engine Oil NJLC0074

WARNING:
I Be careful not to burn yourself, as the engine oil is hot.
I Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine com-
ponents.
2. Stop engine and wait more than 10 minutes.
SLC287B 3. Remove drain plug and oil filler cap.
4. Drain oil and refill with new engine oil.
Oil Specification and Viscosity (Except for Europe):
I API CD, CE, CF or CF-4
Oil Specification and Viscosity (For Europe):
I API grade CF-4
Refer to MA-21, “RECOMMENDED FLUIDS AND LUBRI-
CANTS”.
Refill oil capacity (Approximately):
Unit:  (Imp qt)

JLC288B Without oil filter

4.9 (4-3/8)
change
Drain and refill
With oil filter
5.2 (4-5/8)
change

Dry engine (engine overhaul) 6.3 (5-1/2)

CAUTION:
I Be sure to clean drain plug and install with new washer.
Drain plug:
: 29 - 39 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
I The refill capacity depends on the oil temperature and
drain time. Use these specifications for reference only.
Always use the dipstick to determine when the proper
amount of oil is in the engine.
5. Check oil level.
6. Start engine and check area around drain plug and oil filter for
oil leakage.
7. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.

LC-32
ENGINE LUBRICATION SYSTEM YD
Oil Filter Bracket

Oil Filter Bracket NJLC0075

GI

MA

EM

EC

FE

CL
JLC301B

REMOVAL AND INSTALLATION MT

NJLC0075S01
1. Remove the undercover.
2. Steer the front wheel to the right. AT
3. Remove the right splash cover.
4. Remove the oil filter bracket bolt.
5. Reinstall all removed parts in the reverse order of removal.
AX
I Insert the top mounting bolt to the oil filter bracket beforehand,
and set the oil filter bracket to the installation location. SU
6. After warming up the engine, check for engine oil leakage and
oil level. Refer to LC-32, “Changing Engine Oil”.
BR

Changing Oil Filter NJLC0076 ST

RS

BT

HA

SC

EL

IDX

JLC289B

LC-33
 ENGINE LUBRICATION SYSTEM YD
Changing Oil Filter (Cont’d)
REMOVAL NJLC0076S01
1. Using a socket wrench [plane-to-plane width: 17 mm (0.67 in)],
loosen the filter body approximately four turns.

JLC290B

2. Drain the oil after matching the “DRAIN” arrow mark at the
bottom of the filter body to the protrusion on the oil filter
bracket.
I Catch the oil with a pan or cloth.
CAUTION:
I The drained oil flows over the right surface of the filter
body.
I Completely wipe clean any engine oil remaining on the
filter body or vehicle.
3. Remove the filter body, then remove the oil filter element.
JLC291B

4. Remove the O-ring from the filter body.

I Push the O-ring in one direction, lift the slack part using
fingers, and remove the O-ring from the filter body.
CAUTION:
Do not use wires or flat-bladed screwdrivers etc. as they may
cause damage to the filter body.

JLC292B

INSTALLATION NJLC0076S02
1. Completely remove all foreign objects adhering to the inside of
the filter body or O-ring mounting area (body side and bracket
side).
2. Install the oil filter element and O-ring to the filter body.
I Push the oil filter element into the filter body completely.
3. Install the filter body to the oil filter bracket.
: 20 - 24 N·m (2.0 - 2.5 kg-m, 15 - 18 ft-lb)
4. After warming up the engine, check for engine oil leakage and
oil level. Refer to LC-32, “Changing Engine Oil”.

LC-34
ENGINE LUBRICATION SYSTEM YD
Oil Cooler

Oil Cooler NJLC0077

GI

MA

EM

EC

FE

CL
JLC312B

MT
REMOVAL AND INSTALLATION NJLC0077S01
1. Draining the coolant AT
Refer to LC-47, “Changing Engine Coolant”.
2. Remove the exhaust front tube.
AX

SU

BR
3. Reinstall all removed parts in the reverse order of removal.
I Confirm that no foreign objects are adhering to the installation
ST
planes of the oil cooler or block.
I Tighten the connecting bolt after aligning the stopper on the RS
cylinder block side with protrusion of the oil cooler.
4. After warming up the engine, check for engine oil leakage and
oil level. Refer to LC-32, “Changing Engine Oil”. BT

HA
JLC342B

SC

EL

IDX

SLC359B

LC-35
 ENGINE LUBRICATION SYSTEM YD
Service Data and Specifications (SDS)

Service Data and Specifications (SDS)

OIL PRESSURE CHECK =NJLC0048

Approximate discharge pressure

Engine speed kPa (bar, kg/cm2, psi)
rpm
Sedan Hatchback

Idle speed More than 98 (0.98, 1.0, 14) More than 140 (1.40, 1.43, 20.3)

2,000 More than 265 (2.65, 2.7, 38) More than 270 (2.69, 2.75, 39.1)

4,000 More than 402 (4.02, 4.1, 58) More than 430 (4.29, 4.38, 62.3)

REGULATOR VALVE INSPECTION NJLC0049

Unit: mm (in)

Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0038)

OIL PUMP INSPECTION NJLC0050

Unit: mm (in)

Body to outer rotor radial clearance 0.114 - 0.260 (0.0045 - 0.0102)

Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)

Body to inner rotor axial clearance 0.050 - 0.090 (0.0020 - 0.0035)

Body to outer rotor axial clearance 0.030 - 0.190 (0.0012 - 0.0075)

Inner rotor to brazed portion of housing clearance 0.045 - 0.091 (0.0018 - 0.0036)

ENGINE OIL CAPACITY NJLC0078

Unit:  (Imp qt)

Without oil filter change 4.9 (4-3/8)

Drain and refill (Approximately)
With oil filter change 5.2 (4-5/8)

Dry engine (engine overhaul) 6.3 (5-1/2)

LC-36
 ENGINE COOLING SYSTEM YD
Precautions

Precautions
LIQUID GASKET APPLICATION PROCEDURE
1. Use a scraper to remove all traces of old liquid gasket from
NJLC0051
GI
mating surfaces and grooves. Also, completely clean any oil
from these areas. MA
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket.)
I For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm EM
(0.157 to 0.197 in).
I For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
EC
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant. FE

CL

AEM080
MT
Preparation
SPECIAL SERVICE TOOLS AT
NJLC0052

Tool number
Description AX
Tool name

WS39930000 Pressing the tube of liquid gasket

Tube presser
SU

BR
NT052

EG17650301 Adapting radiator cap tester to radiator filler neck

Radiator cap tester a: 28 (1.10) dia. ST
adapter b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in) RS

NT564
BT
KV99103510 Installing radiator upper and lower tanks
Radiator plate pliers A
HA
NT224

KV99103520 Removing radiator upper and lower tanks SC

Radiator plate pliers B

NT225
EL

IDX

LC-37
 ENGINE COOLING SYSTEM YD
Cooling Circuit

Cooling Circuit NJLC0053

SLC536B

LC-38
ENGINE COOLING SYSTEM YD
Cooling Circuit (Cont’d)

GI

MA

EM

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX
SLC537B

LC-39
 ENGINE COOLING SYSTEM YD
System Check

System Check NJLC0054

WARNING:
Never remove the radiator cap when the engine is hot; serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap and carefully remove it by
turning it a quarter turn to allow built-up pressure to escape
and then turn the cap all the way off.
CHECKING COOLING SYSTEM HOSES NJLC0054S01
Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATOR NJLC0054S02
Check radiator for mud or clogging. If necessary, clean radiator as
follows.
I Be careful not to bend or damage the radiator fins.
I When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, radiator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1. Apply water by hose to the back side of the radiator core ver-
tically downward.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor.
4. Blow air into the back side of radiator core vertically downward.
I Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 ,
71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.

CHECKING RADIATOR CAP NJLC0054S03

To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
SLC755AC

Pull the negative pressure valve to open it.

Check that it closes completely when released.
I Check the radiator cap negative pressure valve for contamina-
tion or damage to the valve seat.
I Move the negative pressure valve to check for abnormalities to
the opening/shutting operation.
CAUTION:
I Be sure to perform the inspections after cooling down the
engine.
I Before connecting the radiator cap to the tester, apply
SMA967B engine coolant to the cap sealing.

LC-40
 ENGINE COOLING SYSTEM YD
System Check (Cont’d)
I Replace the radiator cap if abnormalities are found with the
negative pressure valve, or if the valve opening pressure is out
of the standard range. GI

MA

EM

CHECKING COOLING SYSTEM FOR LEAKS NJLC0054S04

To check for leakage, apply pressure to the cooling system with a EC
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) FE
CAUTION:
I Higher than the specified pressure may cause radiator
damage. CL
I Be sure to perform the inspections after cooling down the
engine.
MT
SLC756AA
I Use a hose adapter between the cap tester and filler neck
to prevent the radiator filler neck from deforming.
I If any abnormalities are found, repair or replace the malfunc- AT
tioning parts.

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

LC-41
 ENGINE COOLING SYSTEM YD
Water Pump

Water Pump
REMOVAL AND INSTALLATION =NJLC0055

JLC294B

REMOVAL NJLC0056
CAUTION:
I When removing water pump assembly, be careful not to
get engine coolant on drive belt.
I Water pump cannot be disassembled and should be
replaced as a unit.
1. Remove the undercover, splash cover (right), and accessory
belt.
2. Drain engine coolant. Refer to LC-47, “Changing Engine Cool-
ant”.
3. Support the bottom of the oil pan with a floor jack etc., and
remove the right engine mount bracket (front side of the
engine).
4. Remove the water pump pulley.
I Loosen the pulley bolts after fixing the pulley using a screw-
driver etc.
5. Remove engine mount brackets.
6. Remove the water pump.

LC-42
ENGINE COOLING SYSTEM YD
Water Pump (Cont’d)
INSPECTION =NJLC0057
I Check for rust and contamination adhering to the water pump
and vane. GI
I Turn the pump shaft by hand, and check that the pump turns
smoothly without looseness.
I After installing water pump, and check for leaks using radiator
MA
cap tester.
INSTALLATION EM
NJLC0058
I Install the parts in the reverse order of removal.
I Install the water pump pulley with the front mark (painted white,
used to prevent errors during assembly) facing the front of the
engine. Refer to the figure above.
I After installing water pump, and check for leaks using radiator EC
cap tester.

FE

CL

MT
Thermostat
REMOVAL AND INSTALLATION AT
NJLC0059

AX

SU

BR

ST

RS

BT

HA

SC

EL

JLC538B IDX

LC-43
 ENGINE COOLING SYSTEM YD
Thermostat (Cont’d)

SLC360BB

I Be careful not to spill coolant over engine compartment.

Use a rag to absorb coolant.

1. Drain engine coolant. Refer to LC-47, “Changing Engine Cool-

ant”.
2. Remove exhaust manifold cover.
3. Remove water inlet.
4. Remove thermostat.

5. Install thermostat with jiggle valve facing upward.

I Carefully install the rubber ring to the flange of the
thermostat, making sure it does not slip out of place.
6. After installation and refilling coolant, run engine for a few
minutes, and check for leaks.

JLC300B

LC-44
 ENGINE COOLING SYSTEM YD
Thermostat (Cont’d)
INSPECTION NJLC0060
1. Check valve seating condition at ordinary room temperatures.
It should seat tightly. GI
2. Check valve opening temperature and maximum valve lift.
Standard MA
Valve opening temperature 80 - 84°C (176 - 183°F)

Valve lift More than 10 mm/95°C EM

(0.39 in/203°F)

SLC252B 3. Then check if valve closes at 5°C (9°F) below valve opening
temperature.

EC

FE

CL

MT
Radiator
COMPONENTS AT
NJLC0083

AX

SU

BR

ST

RS

BT

HA

SC

EL

SLC302BC IDX

LC-45
 ENGINE COOLING SYSTEM YD
Radiator (Cont’d)
REMOVAL AND INSTALLATION =NJLC0063
1. Remove under cover.
2. For Sedan, drain engine coolant from radiator by drain plug,
and for Hatchback, drain engine coolant by removing lower
radiator hose.
3. Disconnect radiator upper and lower hoses.
4. Remove radiator shroud.
5. Disconnect reservoir tank hose.
6. Remove radiator mounting bracket.
7. Remove radiator.
8. After repairing or replacing radiator, install any part removed in
reverse order of removal.
When filling radiator with engine coolant, refer to LC-47,
“Changing Engine Coolant”.

Cooling Fan NJLC0064

COMPONENTS NJLC0064S01

JLC347B

CONTROL SYSTEM NJLC0064S02

Cooling fans are controlled by ECM. For details, refer to EC-368,
“TROUBLE DIAGNOSIS FOR OVERHEAT”.

LC-46
 ENGINE COOLING SYSTEM YD
Changing Engine Coolant

Changing Engine Coolant NJLC0079

WARNING:
To avoid the danger of being scalded, never change the engine GI
coolant when the engine is hot.
Wrap a thick cloth around cap and carefully remove the cap.
First turn the cap a quarter of a turn to release built-up pres- MA
sure. Then turn the cap all the way.
— DRAINING ENGINE COOLANT — NJLC0079S01
EM
1. Set air conditioning system as follows to prevent engine cool-
ant from remaining in the system.
SLC344BB
a. Turn ignition switch ON and set temperature controller to maxi-
mum hot position.
b. Wait 10 seconds before turning ignition switch OFF. EC

FE

CL

JLC295B
MT
2. Open radiator drain plug at the bottom of radiator or remove
lower radiator hose, and remove radiator filler cap to drain AT
engine coolant.
3. Remove reservoir tank, drain engine coolant, then clean res-
ervoir tank. AX
I Be careful not to allow engine coolant to contact drive
belts.
4. Cover the exhaust tube heat shield to prevent from splashing SU
engine coolant.
BR
SMA033D

ST

RS

BT

HA

SC

EL

IDX

LC-47
 ENGINE COOLING SYSTEM YD
Changing Engine Coolant (Cont’d)
5. Remove drain plug of cylinder block and air relief plug.
6. Check drained engine coolant for contaminants such as rust,
corrosion or discoloration. If contaminated flush engine cooling
system, refer to LC-49, “FLUSHING COOLING SYSTEM”.
7. Blow the engine coolant around the exhaust tube heat shield.

JLC318B

JLC345B

SLC341B

— REFILLING ENGINE COOLANT — NJLC0079S02

1. Install reservoir tank, radiator drain plug or lower radiator hose
and cylinder block drain plug.
I Apply sealant to the thread of cylinder block drain plugs.
: 8 - 11 N·m (0.8 - 1.2 kg-m, 70 - 104 in-lb)
2. Fill radiator slowly with engine coolant until engine coolant
spills from the air relief plugs, then install air relief plugs.
I Location of air relief plugs
Water inlet and rear side intake manifold water tubes
I Fill engine coolant to the level of the radiator cap at a rate of
JLC298B 2 (1-3/4 Imp qt)/min or lower.
(Close the plugs in order starting with the location from where
the engine coolant began spilling out.)
CAUTION:
If the filling rate is too fast, this could lead to air being mixed
in the engine coolant. Be sure to fill the engine coolant slowly
according to the rate indicated above.
I Replace the copper washer of the air relief plug.
Air relief plug:
: 6.7 - 7.9 N·m (0.68 - 0.81 kg-m, 59 - 70 in-lb)
I Use genuine NISSAN anti-freeze coolant or equivalent
mixed with water (distilled or demineralized).

LC-48
 ENGINE COOLING SYSTEM YD
Changing Engine Coolant (Cont’d)
Refer to MA-21, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Engine coolant capacity (With reservoir tank):
8.7  (7-5/8 Imp qt) GI
Reservoir tank engine coolant capacity:
0.7  (5/8 Imp qt) MA
I Pour engine coolant through engine coolant filler neck
slowly to allow air in system to escape.
3. Fill radiator and reservoir tank to specified level. EM
4. Warm up engine to normal operating temperature without
radiator cap installed.
SMA182B
I If engine coolant overflows radiator filler hole, install
radiator cap.
5. Run engine at 3,000 rpm for 10 seconds and return to idle EC
speed with radiator cap installed.
I Repeat two or three times.
Watch engine coolant temperature gauge so as not to over- FE
heat the engine.
6. Stop engine and cool it down.
I Cool down using a fan to reduce the time.
CL
I If necessary, refill radiator up to filler neck with engine coolant.
SMA412B
7. Refill reservoir tank to MAX level line with engine coolant. MT
8. Repeat steps 4 through 7 two or more times with radiator cap
installed until engine coolant level no longer drops.
9. Check engine cooling system for leaks with engine running. AT
10. Warm up engine, and check for sound of engine coolant flow
while running engine from idle up to 3,000 rpm with heater AX
temperature controller set at several positions between COOL
and HOT.
I Sound may be noticeable at heater water cock. SU
11. If sound is heard, bleed air from cooling system by repeating
steps 4 through 7 until engine coolant level no longer drops
I Clean excess engine coolant from engine. BR
— FLUSHING COOLING SYSTEM — NJLC0079S03
1. Open air relief plug. ST
2. Fill radiator with water until water spills from the air relief hole,
then close air relief plug. Fill radiator and reservoir tank with
water and reinstall radiator cap. RS
3. Run engine and warm it up to normal operating temperature.
4. Rev engine two or three times under no-load. BT
5. Stop engine and wait until it cools down.
6. Drain water.
7. Repeat steps 1 through 6 until clear water begins to drain from HA
radiator.
SC

EL

IDX

LC-49
 ENGINE COOLING SYSTEM YD
Radiator (Aluminum type)

Radiator (Aluminum type) =NJLC0082

Refer to LC-21, “Radiator (Aluminum type)”.

Overheating Cause Analysis NJLC0070

Symptom Check items

Water pump malfunction Worn or loose drive belt

Thermostat stuck closed —

Dust contamination or
Poor heat transfer Damaged fins paper clogging —

Mechanical damage

Clogged radiator cooling Excess foreign material

tube (rust, dirt, sand, etc.)

Cooling fan does not oper-

ate

Reduced air flow High resistance to fan rota- Fan assembly —

tion

Damaged fan blades

Damaged radiator shroud — — —

Improper engine coolant

— — —
mixture ratio
Cooling sys-
tem parts Poor engine coolant quality — Engine coolant viscosity —
malfunction Loose clamp
Cooling hose
Cracked hose

Water pump Poor sealing

Loose
Radiator cap
Poor sealing
Engine coolant leaks
O-ring for damage, dete-
rioration or improper fit-
Insufficient coolant ting
Radiator
Cracked radiator tank

Cracked radiator core

Reservoir tank Cracked reservoir tank

Cylinder head deteriora-

Exhaust gas leaks into tion
Overflowing reservoir tank
cooling system Cylinder head gasket
deterioration

LC-50
 ENGINE COOLING SYSTEM YD
Overheating Cause Analysis (Cont’d)

Symptom Check items

High engine rpm under GI

no load

Driving in low gear for

Abusive driving
extended time MA
Driving at extremely high
speed EM
— Overload on engine
Powertrain system malfunc-
tion

Installed improper size

Except cool- wheels and tires —
ing system EC
parts mal- Dragging brakes
function
Improper ignition timing
FE
Blocked bumper —

Installed car brassiere

Blocked radiator grille
CL
Mud contamination or
Blocked or restricted air paper clogging —
flow
Blocked radiator — MT
Blocked condenser
Blocked air flow
Installed large fog lamp
AT

AX

SU

BR

Service Data and Specifications (SDS) ST

THERMOSTAT NJLC0071

Valve opening temperature 80 - 84°C (176 - 183°F)

RS
Valve lift More than 10 mm/95°C (0.394 in/203°F)

RADIATOR BT
NJLC0073
2
Unit: kPa (bar, kg/cm , psi)

Cap relief pressure

Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14) HA
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)

Leakage test pressure 157 (1.57, 1.6, 23) SC

ENGINE COOLANT CAPACITY NJLC0080
Unit:  (Imp qt) EL
With reservoir tank 8.7 (7-5/8)

Reservoir tank 0.7 (5/8) IDX

LC-51
NOTES