Engine Cooling System: Section
Engine Cooling System: Section
Engine Cooling System: Section
E
CONTENTS
MR20DE RADIATOR CAP ........................................................14 F
RADIATOR CAP : Inspection ..................................14
FUNCTION DIAGNOSIS ............................... 4
RADIATOR .................................................................14
G
DESCRIPTION .................................................... 4 RADIATOR : Inspection ...........................................14
CO-1
Thermostat ............................................................. 32 Removal and Installation ......................................... 53
Heater Thermostat (CVT models) .......................... 32 Disassembly and Assembly .................................... 54
Water Control Valve ............................................... 32 Inspection ................................................................ 54
QR25DE
WATER PUMP ................................................... 55
FUNCTION DIAGNOSIS ............................. 33 Exploded View ........................................................ 55
Removal and Installation ......................................... 55
DESCRIPTION ................................................... 33 Inspection ................................................................ 56
CO-2
Draining ................................................................... 68 Exploded View .........................................................81
Refilling ................................................................... 69 Removal and Installation .........................................81 A
Flushing ................................................................... 70 Inspection ................................................................82
CO-3
DESCRIPTION
< FUNCTION DIAGNOSIS > [MR20DE]
FUNCTION DIAGNOSIS
DESCRIPTION
M/T
M/T : Engine Cooling System INFOID:0000000001160768
JPBIA0703GB
JPBIA0704GB
CO-4
DESCRIPTION
< FUNCTION DIAGNOSIS > [MR20DE]
CVT
A
CVT : Engine Cooling System INFOID:0000000001160770
CO
JPBIA0705GB
I
JPBIA0706GB
CO-5
OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [MR20DE]
SYMPTOM DIAGNOSIS
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart INFOID:0000000001160772
CO-6
OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [MR20DE]
Symptom Check items
A
High engine rpm under no
load
Driving in low gear for ex-
Abusive driving CO
tended time
Driving at extremely high
speed
— Overload on engine C
Power train system mal-
function
Installed improper size
Except cool- —
wheels and tires D
ing system
parts mal- Dragging brakes
function
Improper ignition timing
E
Blocked bumper —
Installed car brassiere
Blocked radiator grille Mud contamination or paper F
Blocked or restricted air clogging —
flow
Blocked radiator —
Blocked condenser G
Blocked air flow
Installed large fog lamp
CO-7
PRECAUTIONS
< PRECAUTION > [MR20DE]
PRECAUTION
PRECAUTIONS
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000001297938
NOTE:
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS-
TEM).
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-III.
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000001188559
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIRBAG” and
“SEAT BELT” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIRBAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
CO-8
PREPARATION
< PREPARATION > [MR20DE]
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000001160774
CO
Tool number
Description C
Tool name
KV99103510 Installing radiator upper and lower tanks
Radiator plate pliers A
D
E
S-NT224
S-NT225
H
Commercial Service Tools INFOID:0000000001189167
I
Tool name Description
Radiator cap tester Checking radiator and radiator cap
J
PBIC1982E
Radiator cap tester adapter Adapting radiator cap tester to radiator cap L
and water outlet (front) filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia. M
Unit: mm (in)
S-NT564 N
CO-9
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [MR20DE]
ON-VEHICLE MAINTENANCE
ENGINE COOLANT
Inspection INFOID:0000000001160775
LEVEL
• Check that the reservoir tank engine coolant level is within the
“MIN” to “MAX” when the engine is cool.
A : MAX
B : MIN
• Adjust the engine coolant level if necessary.
JPBIA0102ZZ
LEAKAGE
• To check for leakage, apply pressure to the cooling system with the
radiator cap tester (commercial service tool) (A) and the radiator
cap tester adapter (commercial service tool) (B).
age.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
• If anything is found, repair or replace damaged parts.
Draining INFOID:0000000001160776
WARNING:
• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine
coolant escaping from radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres-
sure. Then turn it all the way.
1. Remove engine under cover.
2. Open radiator drain plug (1) at the bottom of radiator, and then
remove radiator cap.
: Vehicle front
CAUTION:
Perform this step when engine is cold.
• When draining all of engine coolant in the system, open water
drain plugs on cylinder block. Refer to CO-16, "Exploded
View".
JPBIA0795ZZ
3. Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing.
• Removal of engine mounting insulator (RH) is necessary. Refer to EM-75, "M/T : Exploded View" (M/T
models) or EM-81, "CVT : Exploded View" (CVT models).
CO-10
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [MR20DE]
• Move reservoir tank (3), and then remove it numerical order as
shown in the figure. A
: Vehicle front
CO
JPBIA0891ZZ
D
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to CO-12, "Flushing".
Refilling INFOID:0000000001160777 E
: Vehicle front
PBIC3802E L
CO-11
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [MR20DE]
6. Refill reservoir tank to “MAX” level line with engine coolant.
A : MAX
B : MIN
JPBIA0102ZZ
CO-12
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [MR20DE]
3. Disconnect heater hose (1) at position ( ) in the figure.
A
: Vehicle front
PBIC3802E
D
4. Fill radiator and reservoir tank with water and reinstall radiator cap.
• When engine coolant over flows disconnected heater hose, connect heater hose, and continue filling the
engine coolant.
E
5. Install electric throttle control actuator and air duct and resonator assembly. Refer to EM-27, "Exploded
View" and EM-25, "Exploded View".
6. Run the engine and warm it up to normal operating temperature.
F
7. Rev the engine two or three times under no-load.
8. Stop the engine and wait until it cools down.
9. Drain water from the system. Refer to CO-10, "Draining". G
10. Repeat steps 1 through 9 until clear water begins to drain from radiator.
CO-13
RADIATOR
< ON-VEHICLE MAINTENANCE > [MR20DE]
RADIATOR
RADIATOR CAP
RADIATOR CAP : Inspection INFOID:0000000001193706
A : Valve seat
B : Metal plunger
- Check that valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
- Check that valve seat has no soil and damage.
JPBIA0108ZZ
SMA967B
PBIC5122J
CO-14
RADIATOR
< ON-VEHICLE MAINTENANCE > [MR20DE]
4. Blow air into the back side of radiator core vertically downward.
• Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71 psi) and keep distance more than 30 cm A
(11.8 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
CO
CO-15
RADIATOR
< ON-VEHICLE REPAIR > [MR20DE]
ON-VEHICLE REPAIR
RADIATOR
Exploded View INFOID:0000000001160781
REMOVAL
M/T models (Except for Russia)
JPBIA0737GB
CO-16
RADIATOR
< ON-VEHICLE REPAIR > [MR20DE]
M/T models (for Russia) and CVT models
A
CO
I
JPBIA0738GB
DISASSEMBLY
M
CO-17
RADIATOR
< ON-VEHICLE REPAIR > [MR20DE]
JPBIA0579GB
REMOVAL
WARNING:
• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine
coolant escaping from radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres-
sure. Then turn it all the way.
1. Remove engine under cover.
2. Drain engine coolant from radiator. Refer to CO-10, "Draining".
CAUTION:
Perform this step when the engine is cold.
3. Remove air duct (inlet). Refer to EM-25, "Exploded View".
4. Remove air guide (upper). Refer to HA-59, "MR20DE (M/T) : Exploded View". (M/T models)
5. Disconnect harness connector from fan motor, and move harness to aside.
6. Remove radiator hose (upper) and reservoir tank hose.
7. Remove mounting bracket (RH and LH) and mounting rubber (upper) to tilt radiator frontward.
8. Remove radiator hose (lower).
9. Remove radiator and cooling fan assembly/
CAUTION:
Be careful not to damage or scratch radiator core.
10. Remove cooling fan assembly from radiator.
CAUTION:
Be careful not to damage radiator core when removing.
INSTALLATION
Installation is the reverse order of removal.
PREPARATION
CO-18
RADIATOR
< ON-VEHICLE REPAIR > [MR20DE]
1. Attach the spacer to the tip of radiator plate pliers A (SST).
Spacer specification: 1.5 mm (0.059 in) thick × 18 mm (0.71 in) A
wide × 8.5 mm (0.335 in) long.
CO
SLC655C
D
2. Check that when radiator plate pliers A [SST: KV99103510] are closed dimension H′′ is approx. 7.6 mm
(0.299 in).
3. Adjust dimension H′′ with the spacer thickness, if necessary. E
DISASSEMBLY
1. Remove upper and lower tanks with a radiator plate pliers B
(SST). F
SLC903
I
• Grip the crimped edge and bend it upwards so that radiator
plate pliers B [SST: KV99103520] slips off.
CAUTION: J
Never bend excessively.
SLC893
M
• In areas where radiator plate pliers B [SST: KV99103520] can-
not be used, use screwdriver to bend the edge up.
CAUTION:
Be careful not to damage tank. N
P
SLC930
CO-19
RADIATOR
< ON-VEHICLE REPAIR > [MR20DE]
3. Check the edge stands straight up.
SLC931
ASSEMBLY
1. Clean contact portion of tank.
SLC932
SLC917A
SLC904
CO-20
RADIATOR
< ON-VEHICLE REPAIR > [MR20DE]
CO
JPBIA0903ZZ
D
B. Keep tool perpendicular to the radiator C. Grip is insufficient
a. 90°
E
• Use pliers in the locations where radiator plate pliers A [SST:
KV99103510] cannot be used.
F
H
SLC897
SLC554A
L
5. Check that there is no leakage.
Refer to CO-21, "Inspection".
Inspection INFOID:0000000001197048
M
JPBIA0736ZZ
CO-21
RADIATOR
< ON-VEHICLE REPAIR > [MR20DE]
2. Check for leakage by soaking radiator in water container with
the testing pressure applied.
SLC934
CO-22
COOLING FAN
< ON-VEHICLE REPAIR > [MR20DE]
COOLING FAN
A
Exploded View INFOID:0000000001160784
CO
I
JPBIA0793GB
REMOVAL M
1. Remove engine under cover.
2. Drain engine coolant from radiator. Refer to CO-10, "Draining".
CAUTION: N
Perform this step when the engine is cold.
3. Remove air duct (inlet). Refer to EM-25, "Exploded View".
4. Remove air guide upper. Refer to HA-59, "MR20DE (M/T) : Exploded View". (M/T models) O
5. Disconnect harness connector from resistor and fan motor, and move harness to aside.
6. Remove radiator hose (upper) and reservoir tank hose. Refer to CO-16, "Exploded View".
P
7. Remove mounting bracket (RH and LH) and mounting rubber (upper) to tilt radiator frontward. Refer to
CO-16, "Exploded View".
8. Remove cooling fan assembly.
CAUTION:
Be careful not to damage or scratch on radiator core when removing.
INSTALLATION
Note the following, and install in the reverse order of removal.
CO-23
COOLING FAN
< ON-VEHICLE REPAIR > [MR20DE]
CAUTION:
Only use genuine parts for fan shroud mounting bolt and observe the specified torque (to prevent
radiator from being damaged).
NOTE:
Cooling fan is controlled by ECM. For details, refer to ECM-287, "Description".
Disassembly and Assembly INFOID:0000000001160786
DISASSEMBLY
1. Remove cooling fan mounting nuts, and then remove the cooling fans (RH and LH).
2. Remove fan motors (RH and LH).
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
CAUTION:
RH and LH cooling fans are different. Be careful not to misassemble them.
• Install each fan in the following position.
CO-24
WATER PUMP
< ON-VEHICLE REPAIR > [MR20DE]
WATER PUMP
A
Exploded View INFOID:0000000001160788
CO
G
KBIA4510J
I
REMOVAL
1. Drain engine coolant from radiator. Refer to CO-10, "Draining".
CAUTION: J
Perform this step when the engine is cold.
2. Remove front fender protector (RH). Refer to EXT-21, "Exploded View".
3. Remove drive belt. Refer to EM-15, "Removal and Installation". K
4. Remove water pump.
• Engine coolant leaks from cylinder block, so have a receptacle ready below.
CAUTION: L
• Handle water pump vane so that it does not contact any other parts.
• Water pump cannot be disassembled and should be replaced as a unit.
INSTALLATION M
Install in the reverse order of removal.
Inspection INFOID:0000000001160790
N
INSPECTION AFTER REMOVAL
• Check visually that there is no significant dirt or rusting on water
pump body and vane (A). O
• Check that there is no looseness in vane shaft, and that it turns
smoothly when rotated by hand.
• Replace water pump, if necessary. P
PBIC3313J
CO-25
WATER PUMP
< ON-VEHICLE REPAIR > [MR20DE]
INSPECTION AFTER INSTALLATION
• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-10, "Inspection".
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.
CO-26
THERMOSTAT
< ON-VEHICLE REPAIR > [MR20DE]
THERMOSTAT
A
Exploded View INFOID:0000000001160791
CO
L
JPBIA0580GB
P
REMOVAL
1. Drain engine coolant from radiator. Refer to CO-10, "Draining".
CAUTION:
Perform this step when engine is cold.
2. Disconnect the battery cable from the negative terminal. Refer to PG-133, "Exploded View".
3. Add paint mark, then disconnect radiator hose (lower) from water inlet. Refer to CO-16, "Exploded View".
CO-27
THERMOSTAT
< ON-VEHICLE REPAIR > [MR20DE]
4. Remove water inlet and thermostat.
• Engine coolant leaks from cylinder block, so have a receptacle ready below.
5. Remove thermostat housing with the following procedure:
a. Remove water pump. Refer to CO-25, "Exploded View".
b. Remove alternator. Refer to CHG-27, "MR20DE MODELS : Exploded View".
c. Disconnect water hoses.
INSTALLATION
Note the following, and install in the reverse order of removal.
Thermostat
• Install thermostat with making rubber ring (1) groove fit to thermo-
stat flange (A) with the whole circumference.
PBIC3315J
2 : Thermostat housing
PBIC3548J
Inspection INFOID:0000000001160793
CO-28
THERMOSTAT
< ON-VEHICLE REPAIR > [MR20DE]
• Fully immerse the heater thermostat (1) in a container (A) filled
with water. Continue heating the water while stirring. A
• Continue heating the heater thermostat for 5 minutes or more after
bringing the water to a boil.
• Quickly take the heater thermostat out of the hot water, measure
CO
the heater thermostat within 10 seconds.
JPBIA0318ZZ
D
• Place dial indicator (A) on the pellet (B) and measure the elonga-
tion from the initial state.
E
Standard
: Refer to CO-32, "Heater Thermostat (CVT models)".
• If out of the standard, replace heater thermostat. F
G
JPBIA0319ZZ
CO-29
WATER OUTLET
< ON-VEHICLE REPAIR > [MR20DE]
WATER OUTLET
Exploded View INFOID:0000000001160794
JPBIA0581GB
REMOVAL
1. Drain engine coolant from radiator. Refer to CO-10, "Draining".
CAUTION:
Perform this step when engine is cold.
2. Disconnect radiator hose (upper). Refer to CO-16, "Exploded View".
3. Disconnect harness connector from engine coolant temperature sensor.
4. Remove water hoses and heater hoses.
5. Remove water outlet.
6. Remove engine coolant temperature sensor from water outlet, if necessary.
CO-30
WATER OUTLET
< ON-VEHICLE REPAIR > [MR20DE]
INSTALLATION
Note the following, and install in the reverse order of removal. A
Water Control Valve
• Install water control valve with making rubber ring (1) groove fit to
water control valve flange (A) with the whole circumference. CO
PBIC4682E
E
• Install water control valve (2) with the arrow (A) facing up and the
frame center part (B) facing upwards.
F
1 : Water outlet
PBIC3319J
Inspection INFOID:0000000001160796 I
CO-31
SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [MR20DE]
Radiator INFOID:0000000001160798
Thermostat INFOID:0000000001160799
Standard
Standard
Reference value
Standard
CO-32
DESCRIPTION
< FUNCTION DIAGNOSIS > [QR25DE]
FUNCTION DIAGNOSIS A
DESCRIPTION
M/T
CO
M/T : Engine Cooling System INFOID:0000000001202913
JPBIA0707GB
M
CO-33
DESCRIPTION
< FUNCTION DIAGNOSIS > [QR25DE]
M/T : Engine Cooling System Schematic INFOID:0000000001202914
JPBIA0708GB
CVT
CO-34
DESCRIPTION
< FUNCTION DIAGNOSIS > [QR25DE]
CVT : Engine Cooling System INFOID:0000000001202915
CO
K
JPBIA0709GB
CO-35
DESCRIPTION
< FUNCTION DIAGNOSIS > [QR25DE]
CVT : Engine Cooling System Schematic INFOID:0000000001202916
JPBIA0710GB
CO-36
OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [QR25DE]
SYMPTOM DIAGNOSIS A
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart INFOID:0000000001160729
CO
CO-37
OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [QR25DE]
Symptom Check items
High engine rpm under no
load
Driving in low gear for ex-
Abusive driving
tended time
Driving at extremely high
speed
— Overload on engine
Powertrain system malfunc-
tion
Installed improper size
Except cool- —
wheels and tires
ing system
parts mal- Dragging brakes
function
Improper ignition timing
Blocked bumper —
Installed car brassiere
Blocked radiator grille Mud contamination or paper
Blocked or restricted air clogging —
flow
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp
CO-38
PRECAUTIONS
< PRECAUTION > [QR25DE]
PRECAUTION A
PRECAUTIONS
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect CO
INFOID:0000000001570494
NOTE:
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS- C
TEM).
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. D
If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder. E
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
F
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables. G
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the H
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated. I
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.) J
6. Perform a self-diagnosis check of all control units using CONSULT-III.
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
K
PRE-TENSIONER" INFOID:0000000001569909
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain L
types of collision. Information necessary to service the system safely is included in the “SRS AIRBAG” and
“SEAT BELT” of this Service Manual.
WARNING: M
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
N
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIRBAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this O
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
P
CO-39
PREPARATION
< PREPARATION > [QR25DE]
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000001160725
Tool number
Description
Tool name
KV99103510 Installing radiator upper and lower tanks
Radiator plate pliers A
S-NT224
S-NT225
PBIC1982E
Radiator cap tester adapter Adapting radiator cap tester to radiator cap
and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564
CO-40
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [QR25DE]
ON-VEHICLE MAINTENANCE A
ENGINE COOLANT
Inspection INFOID:0000000001160730
CO
LEVEL
• Check that the reservoir tank engine coolant level is within the C
“MIN” to “MAX” when the engine is cool.
A : MAX
B : MIN
D
JPBIA0102ZZ
F
LEAKAGE
• To check for leaks, apply pressure to the cooling system with the
radiator cap tester (commercial service tool) (A) and the radiator G
cap tester adapter (commercial service tool) (B).
age. J
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
• If anything is found, repair or replace damaged parts. K
Draining INFOID:0000000001160731
WARNING: L
• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine
coolant escaping from radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres- M
sure. Then turn it all the way.
1. Remove engine under cover.
2. Open radiator drain plug at the bottom of radiator, and then N
remove radiator cap.
CAUTION:
Perform this step when engine is cold. P
• When draining all of engine coolant in the system, open water
drain plugs on cylinder block. Refer to EM-210, "Exploded
View". JPBIA0892ZZ
3. Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing.
CO-41
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [QR25DE]
• Move reservoir tank (3), and then remove it numerical order as
shown in the figure.
: Vehicle front
JPBIA0891ZZ
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush the engine cooling system. Refer to CO-43, "Flushing".
Refilling INFOID:0000000001160732
: Vehicle front
• Lift up the heater hose end approximately 100 mm (3.94 in) (a)
higher than the height at installation.
JPBIA0817ZZ
CO-42
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [QR25DE]
5. Fill radiator (1) to specified level.
CAUTION: A
Never adhere the engine coolant to electronic equipments
(alternator etc.).
• Pour engine coolant through engine coolant filler neck slowly
CO
of less than 2 (2-1/8 US qt, 1-3/4 lmp qt) a minute to allow
air in system to escape.
• When engine coolant overflows disconnected heater hose,
connect heater hose, and continue filling the engine coolant. C
• Use Genuine NISSAN Engine Coolant or equivalent in its
quality mixed with water (distilled or demineralized). Refer to JPBIA0819ZZ
MA-22, "Fluids and Lubricants". D
Engine coolant capacity
(With reservoir tank at “MAX” level)
E
Refer to CO-61, "Periodical Maintenance Specification".
CO-43
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [QR25DE]
• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-210, "Exploded
View".
2. Remove air duct assembly and move electric throttle control actuator to aside. Refer to EM-150,
"Exploded View" and EM-152, "Exploded View".
3. Disconnect heater hose (1) at the position ( ) in the figure.
: Vehicle front
• Lift up the heater hose end approximately 100 mm (3.94 in) (a)
higher than the height at installation.
JPBIA0817ZZ
4. Fill radiator and reservoir tank with water and reinstall radiator cap.
• When engine coolant overflows disconnected heater hose, connect heater hose, and continue filling the
engine coolant.
5. Install air duct assembly and electric throttle control actuator. Refer to EM-150, "Exploded View" and EM-
152, "Exploded View".
6. Run the engine and warm it up to normal operating temperature.
7. Rev the engine two or three times under no-load.
8. Stop the engine and wait until it cools down.
9. Drain water from the system. Refer to CO-41, "Draining".
10. Repeat steps 1 through 9 until clear water begins to drain from radiator.
CO-44
RADIATOR
< ON-VEHICLE MAINTENANCE > [QR25DE]
RADIATOR
A
RADIATOR CAP
RADIATOR CAP : Inspection INFOID:0000000001160734
CO
• Check valve seat of radiator cap.
A : Valve seat C
B : Metal plunger
- Check that valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top. D
- Check that valve seat has no soil and damage.
E
JPBIA0108ZZ
SMA967B
I
PBIC5122J
M
• Replace radiator cap if there is an unusualness related to the above three.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue N
or foreign material.
RADIATOR
O
RADIATOR : Inspection INFOID:0000000001160735
CO-45
RADIATOR
< ON-VEHICLE MAINTENANCE > [QR25DE]
4. Blow air into the back side of radiator core vertically downward.
• 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.
CO-46
RADIATOR
< ON-VEHICLE REPAIR > [QR25DE]
ON-VEHICLE REPAIR A
RADIATOR
Exploded View INFOID:0000000001160736
CO
REMOVAL
C
K
JPBIA0739GB
DISASSEMBLY O
CO-47
RADIATOR
< ON-VEHICLE REPAIR > [QR25DE]
JPBIA0579GB
REMOVAL
WARNING:
• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine
coolant escaping from radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres-
sure. Then turn it all the way.
1. Remove engine under cover.
2. Drain engine coolant from radiator. Refer to CO-41, "Draining".
CAUTION:
Perform this step when the engine is cold.
3. Remove air duct (inlet). Refer to EM-150, "Exploded View".
4. Disconnect harness connector from fan motor, and move it aside.
5. Remove radiator hose (upper) and reservoir tank hose.
6. Remove mounting bracket (RH and LH) and mounting rubber (upper) to tilt radiator frontward.
7. Remove cooling fan assembly (1). Refer to CO-53, "Exploded
View".
CAUTION:
Be careful not to damage radiator core when removing.
KBIA3587J
CO-48
RADIATOR
< ON-VEHICLE REPAIR > [QR25DE]
Installation is the reverse order of removal.
A
Disassembly and Assembly INFOID:0000000001185527
PREPARATION
CO
1. Attach spacer to tip of the radiator plate pliers A (SST).
Spacer specification: 1.5 mm (0.059 in) thick × 18 mm (0.71 in)
wide × 8.5 mm (0.335 in) long.
C
E
SLC655C
2. Check that when the radiator plate pliers A [SST: KV99103510] are closed dimension H′′ is approx. 7.6
mm (0.299 in). F
3. Adjust dimension H′′ with spacer, if necessary.
DISASSEMBLY G
1. Remove upper and lower tanks with the radiator plate pliers B
(SST).
H
J
SLC903
• Grip the crimped edge and bend it upwards so that the radiator K
plate pliers B [SST: KV99103520] slips off.
CAUTION:
Never bend excessively. L
SLC893
N
SLC930
CO-49
RADIATOR
< ON-VEHICLE REPAIR > [QR25DE]
2. Remove sealing rubber.
3. Check the edge stands straight up.
SLC931
ASSEMBLY
1. Clean contact portion of tank.
SLC932
SLC917A
SLC904
CO-50
RADIATOR
< ON-VEHICLE REPAIR > [QR25DE]
CO
JPBIA0903ZZ
D
B. Keep tool perpendicular to the radiator C. Grip is insufficient
a. 90°
E
• Use pliers in the locations where the radiator plate pliers A
[SST: KV99103510] cannot be used.
F
H
SLC897
SLC554A
L
5. Check that there is no leakage. Refer to CO-51, "Inspection".
Inspection INFOID:0000000001160760
M
INSPECTION AFTER ASSEMBLY
1. Apply pressure with the radiator cap tester adapter (commercial N
service tool) (A) and the radiator cap tester (commercial service
tool).
WARNING:
To prevent the risk of hose coming undone while under
pressure, securely fasten it down with hose clamp. P
JPBIA0736ZZ
CO-51
RADIATOR
< ON-VEHICLE REPAIR > [QR25DE]
2. Check for leakage by soaking radiator in water container with
the testing pressure applied.
SLC934
CO-52
COOLING FAN
< ON-VEHICLE REPAIR > [QR25DE]
COOLING FAN
A
Exploded View INFOID:0000000001160740
CO
I
JPBIA0794GB
REMOVAL
M
1. Remove engine under cover.
2. Drain engine coolant from radiator. Refer to CO-41, "Draining".
CAUTION:
Perform this step when the engine is cold. N
3. Remove air duct (inlet). Refer to EM-150, "Exploded View".
4. Disconnect harness connector from fan motor, and move harness to aside.
O
5. Remove radiator hose (upper) and reservoir tank hose. Refer to CO-47, "Exploded View".
6. Remove mounting bracket (RH and LH) and mounting rubber (upper) to tilt radiator frontward. Refer to
CO-47, "Exploded View".
P
7. Remove cooling fan assembly.
CAUTION:
Be careful not to damage or scratch on radiator core when removing.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
CO-53
COOLING FAN
< ON-VEHICLE REPAIR > [QR25DE]
Only use genuine parts for radiator shroud and cooling fan mounting bolt and observe the specified
torque (to prevent radiator from being damaged).
NOTE:
Cooling fan is controlled by ECM. For details, refer to ECQ-300, "Description".
Disassembly and Assembly INFOID:0000000001160762
DISASSEMBLY
1. Remove cooling fan mounting nuts, and then remove the cooling fans (RH and LH).
2. Remove fan motor cover and fan motors (RH and LH).
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
CAUTION:
RH and LH cooling fans are different. Be careful not to misassemble them.
• Install each fan in the following position.
CO-54
WATER PUMP
< ON-VEHICLE REPAIR > [QR25DE]
WATER PUMP
A
Exploded View INFOID:0000000001203532
CO
G
JPBIA0582GB
REMOVAL J
1. Drain engine coolant. Refer to CO-41, "Draining".
CAUTION:
Perform this step when engine is cold. K
2. Remove the following parts.
• Drive belt: Refer to EM-138, "Removal and Installation".
• Drive belt auto-tensioner: Refer to EM-148, "Exploded View". L
• Alternator: Refer to CHG-30, "QR25DE MODELS : Exploded View".
3. Remove water pump.
• Engine coolant leaks from cylinder block, so have a receptacle ready below. M
CAUTION:
• Handle water pump vane so that it does not contact any other parts.
• Water pump cannot be disassembled and should be replaced as a unit.
4. Remove water pump housing with the following procedure: N
a. Remove exhaust manifold cover. Refer to EM-155, "Exploded View".
b. Remove oil level gauge and oil level gauge guide. Refer to EM-161, "Exploded View".
CAUTION: O
Plug the oil level gauge guide opening to prevent oil pan from entering foreign materials.
c. Remove mounting bolts for water pipe.
P
d. Remove water pump housing.
5. Remove exhaust manifold and three way catalyst assembly. Refer to EM-155, "Exploded View".
6. Remove water pipe.
INSTALLATION
Note the following, and install in the reverse order of removal.
• When inserting water pipe end into cylinder block, apply a neutral detergent to O-ring. Then insert it immedi-
ately.
CO-55
WATER PUMP
< ON-VEHICLE REPAIR > [QR25DE]
Inspection INFOID:0000000001203533
KBIA0155E
CO-56
THERMOSTAT AND WATER CONTROL VALVE
< ON-VEHICLE REPAIR > [QR25DE]
THERMOSTAT AND WATER CONTROL VALVE
A
Exploded View INFOID:0000000001203575
M/T models CO
JPBIA0583GB
K
1. Thermostat 2. O-ring 3. Water inlet
4. Clamp 5. Radiator hose (lower) 6. Water control valve
L
7. O-ring 8. Gasket 9. Radiator hose (upper)
10. Water control valve housing (water outlet) 11. Heater hose 12. Clamp
13. Clamp 14. Water hose 15. Water hose
M
Engine coolant temperature
16. Clamp 17. 18. Washer
sensor
19. Heater pipe 20. O-ring 21. Heater hose
22. Water hose 23. Water hose N
A. To radiator B. To heater C. To electric throttle control actuator
D. To oil cooler
: Engine front
O
CVT models P
CO-57
THERMOSTAT AND WATER CONTROL VALVE
< ON-VEHICLE REPAIR > [QR25DE]
JPBIA0584GB
REMOVAL
1. Remove battery. Refer to PG-133, "Exploded View".
2. Disconnect engine room harness connectors at unit sides TCM and ECM, and then move it to aside.
3. Remove battery tray.
4. Remove air duct and air cleaner case assembly. Refer to EM-150, "Exploded View".
5. Drain engine coolant. Refer to CO-41, "Draining".
CAUTION:
Perform this step when engine is cold.
CO-58
THERMOSTAT AND WATER CONTROL VALVE
< ON-VEHICLE REPAIR > [QR25DE]
6. Disconnect radiator hose (lower) at water inlet side. Refer to CO-47, "Exploded View".
7. Disconnect water hose at water inlet side. (CVT models) A
8. Remove water inlet and thermostat.
9. Remove water control valve with the following procedure:
CO
a. Disconnect radiator hose (upper) at water control valve housing (water outlet) side.
b. Disconnect harness connector from engine coolant temperature sensor.
c. Remove CVT fluid level gauge and CVT fluid charging pipe. Refer to TM-550, "QR25DE : Exploded C
View". (CVT models)
d. Disconnect water hoses.
e. Disconnect heated oxygen sensor harness connectors, and remove harness clips from heater pipe. D
f. Remove heater pipe and heater hose.
g. After removing water control valve housing (water outlet), remove water control valve.
INSTALLATION E
Note the following, and install in the reverse order of removal.
Thermostat and Water Control Valve
F
• Install thermostat and water control valve with making rubber ring
groove fit to thermostat flange and water control valve flange with
the whole circumference. (The example in the figure shows ther-
mostat.) G
NOTE:
Same procedure is applied for installation of water control valve.
H
I
PBIC0157E
PBIC0158E
M
Heater Pipe Installation
Apply a neutral detergent to O-ring, then quickly insert the insertion part of heater pipe into cylinder block.
Inspection INFOID:0000000001203576
N
CO-59
THERMOSTAT AND WATER CONTROL VALVE
< ON-VEHICLE REPAIR > [QR25DE]
• After checking the maximum valve lift amount, lower the water temperature and check the valve closing tem-
perature.
Standard
Thermostat : Refer to CO-61, "Thermostat".
Water control valve : Refer to CO-61, "Water control valve".
• If out of the standard, replace either or both thermostat and water control valve.
INSPECTION AFTER INSTALLATION
• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-41, "Inspection".
• Start and warm up engine. Check visually that there is no leakage of engine coolant.
CO-60
SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE]
Radiator INFOID:0000000001204236
E
Unit: kPa (bar, kg/cm2, psi)
Thermostat INFOID:0000000001303608 G
Standard
Valve opening temperature 80.5 - 83.5°C (177 - 182°F) H
Maximum valve lift 8 mm/95°C (0.315 in/203°F)
Valve closing temperature 77°C (171°F)
I
Water control valve INFOID:0000000001303609
Standard
J
Valve opening temperature 93.5 - 96.5°C (200 - 206°F)
Maximum valve lift 8 mm/108°C (0.315 in/226°F)*
Valve closing temperature 90°C (194°F) K
*: Reference data
CO-61
DESCRIPTION
< FUNCTION DIAGNOSIS > [M9R]
FUNCTION DIAGNOSIS
DESCRIPTION
M/T
M/T : Engine Cooling System INFOID:0000000001308708
JPBIA0740GB
JPBIA0741GB
CO-62
DESCRIPTION
< FUNCTION DIAGNOSIS > [M9R]
A/T
A
A/T : Engine Cooling System INFOID:0000000001308710
CO
JPBIA0804GB
I
JPBIA0805GB
CO-63
OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [M9R]
SYMPTOM DIAGNOSIS
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart INFOID:0000000001308712
CO-64
OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [M9R]
Symptom Check items
A
High engine rpm under no
load
Driving in low gear for ex-
Abusive driving CO
tended time
Driving at extremely high
speed
— Overload on engine C
Power train system mal-
function
Installed improper size
Except cool- —
wheels and tires D
ing system
parts mal- Dragging brakes
function
Improper ignition timing
E
Blocked bumper —
Installed car brassiere
Blocked radiator grille Mud contamination or paper F
Blocked or restricted air clogging —
flow
Blocked radiator —
Blocked condenser G
Blocked air flow
Installed large fog lamp
CO-65
PRECAUTIONS
< PRECAUTION > [M9R]
PRECAUTION
PRECAUTIONS
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000001308749
NOTE:
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS-
TEM).
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-III.
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000001308750
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIRBAG” and
“SEAT BELT” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIRBAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
CO-66
PREPARATION
< PREPARATION > [M9R]
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000001308715
CO
Tool number
Description C
Tool name
KV99103510 Installing radiator upper and lower tanks
Radiator plate pliers A
D
E
S-NT224
S-NT225
H
Commercial Service Tools INFOID:0000000001308716
I
Tool name Description
Radiator cap tester Checking radiator and reservoir tank cap
J
PBIC1982E
Radiator cap tester adapter Adapting radiator cap tester to reservoir tank L
cap and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia. M
Unit: mm (in)
S-NT564 N
CO-67
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [M9R]
ON-VEHICLE MAINTENANCE
ENGINE COOLANT
Inspection INFOID:0000000001308717
LEVEL
• Check that the reservoir tank engine coolant level is within the
“MIN” to “MAX” when the engine is cool.
A : MAX
B : MIN
• Regarding engine coolant level check, perform it with engine at
idle.
NOTE:
Engine coolant level rises approximately 15 mm (0.59 in) in the
engine stop.
• Adjust the engine coolant level if necessary. JPBIA0102ZZ
WARNING:
Never remove radiator cap and reservoir tank cap when engine is hot. Serious burns may occur from
high-pressure engine coolant escaping from radiator and reservoir tank.
LEAKAGE
• To check for leakage, apply pressure to the cooling system with the
radiator cap tester (commercial service tool) (A) and the radiator
cap tester adapter (commercial service tool) (B).
age.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
• If anything is found, repair or replace damaged parts.
Draining INFOID:0000000001308718
WARNING:
• Never remove radiator cap and reservoir tank cap when engine is hot. Serious burns may occur from
high-pressure engine coolant escaping from radiator and reservoir tank.
• Wrap a thick cloth around the caps. Slowly turn it a quarter of a turn to release built-up pressure.
Then turn it all the way.
1. Remove engine undercover.
2. Open radiator drain plug at the bottom of radiator, and then
remove reservoir tank cap.
CAUTION:
Perform this step when engine is cold.
JPBIA0892ZZ
CO-68
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [M9R]
3. Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing.
• Removal of fuel filter is necessary. Refer to FL-16, "Exploded View". A
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to CO-70, "Flushing".
CO
Refilling INFOID:0000000001308719
: Vehicle front F
• Enhance heater hose as high as possible.
H
JPBIA0816ZZ
CO-69
ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [M9R]
8. Install air duct assembly. Refer to EM-263, "Exploded View".
9. Warm up engine until opening thermostat. Standard for warming-up time is approximately 10 minutes at
3,000 rpm.
• Check thermostat opening condition by touching radiator hose (upper) to see a flow of warm water.
CAUTION:
Watch water temperature gauge so as not to overheat engine.
10. Stop the engine and cool down to less than approximately 50°C (122°F).
• Cool down using fan to reduce the time.
• If necessary, refill radiator up to filler neck with engine coolant.
CAUTION:
Never adhere the engine coolant to electronic equipments. (alternator etc.)
11. Fill the reservoir tank approximately 15 mm (0.59 in) above the “MAX” level of engine coolant.
NOTE:
Engine coolant level rises approximately 15 mm (0.59 in) in the engine stop.
12. Repeat steps 5 through 10 two or more times with cap (radiator and reservoir tank) installed until engine
coolant level no longer drops.
13. Check cooling system for leakage with engine running.
14. Warm up the 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 position between “COOL” and “WARM”.
• Sound may be noticeable at heater unit.
15. Repeat step 14 three times.
16. If sound is heard, bleed air from cooling system by repeating step 5 through 10 until reservoir tank level no
longer drops.
Flushing INFOID:0000000001308720
: Vehicle front
JPBIA0816ZZ
4. Fill radiator and reservoir tank with water and reinstall radiator cap and reservoir tank cap.
• When engine coolant over flows disconnected heater hose, connect heater hose, and continue filling the
engine coolant.
5. Install air duct assembly. Refer to EM-263, "Exploded View".
6. Run the engine and warm it up to normal operating temperature.
7. Rev the engine two or three times under no-load.
8. Stop the engine and wait until it cools down.
9. Drain water from the system. Refer to CO-68, "Draining".
10. Repeat steps 1 through 9 until clear water begins to drain from radiator.
CO-70
RADIATOR
< ON-VEHICLE MAINTENANCE > [M9R]
RADIATOR
A
RESERVOIR TANK CAP
RESERVOIR TANK CAP : Inspection INFOID:0000000001308721
CO
• Check valve seat of reservoir tank cap.
A : Valve seat C
B : Metal plunger
- Check that valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top. D
- Check that valve seat has no soil and damage.
E
JPBIA0108ZZ
SMA967B
I
PBIC5122J
M
• Replace reservoir tank cap if there is an unusualness related to the above three.
CAUTION:
When installing radiator cap and reservoir tank cap, thoroughly wipe out the radiator filler neck to N
remove any waxy residue or foreign material.
RADIATOR
O
RADIATOR : Inspection INFOID:0000000001308722
CO-71
RADIATOR
< ON-VEHICLE MAINTENANCE > [M9R]
4. Blow air into the back side of radiator core vertically downward.
• 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.
CO-72
RADIATOR
< ON-VEHICLE REPAIR > [M9R]
ON-VEHICLE REPAIR A
RADIATOR
Exploded View INFOID:0000000001308723
CO
REMOVAL
C
K
JPBIA0742GB
DISASSENBLY P
CO-73
RADIATOR
< ON-VEHICLE REPAIR > [M9R]
JPBIA0579GB
REMOVAL
WARNING:
• Never remove radiator cap and reservoir tank cap when engine is hot. Serious burns may occur from
high-pressure engine coolant escaping from radiator and reservoir tank.
• Wrap a thick cloth around the caps. Slowly turn it a quarter of a turn to release built-up pressure.
Then turn it all the way.
1. Remove engine undercover.
2. Drain engine coolant from radiator. Refer to CO-68, "Draining".
CAUTION:
Perform this step when the engine is cold.
3. Remove air duct (inlet). Refer to EM-263, "Exploded View".
4. Remove air inlet hose, air inlet pipe and bracket. Refer to EM-266, "Exploded View".
5. Remove mounting bracket and mounting rubber (upper).
6. Disconnect harness connector from fan motors, and move harness to aside.
7. Disconnect radiator hose (upper).
8. Remove cooling fan assembly.
CAUTION:
Be careful not to damage radiator core when removing.
9. Disconnect reservoir tank hose (upper) from radiator.
10. Disconnect radiator hose (lower).
11. Remove radiator.
CAUTION:
Be careful not to damage or scratch radiator core.
INSTALLATION
Installation is the reverse order of removal.
PREPARATION
CO-74
RADIATOR
< ON-VEHICLE REPAIR > [M9R]
1. Attach the spacer to the tip of radiator plate pliers A (SST).
Spacer specification: 1.5 mm (0.059 in) thick × 18 mm (0.71 in) A
wide × 8.5 mm (0.335 in) long.
CO
SLC655C
D
2. Check that when radiator plate pliers A [SST: KV99103510] are closed dimension H′′ is approximately 7.6
mm (0.299 in).
3. Adjust dimension H′′ with the spacer thickness, if necessary. E
DISASSEMBLY
1. Remove upper and lower tanks with a radiator plate pliers B
(SST). F
SLC903
I
• Grip the crimped edge and bend it upwards so that radiator
plate pliers B [SST: KV99103520] slips off.
CAUTION: J
Never bend excessively.
SLC893
M
• In areas where radiator plate pliers B [SST: KV99103520] can-
not be used, use screwdriver to bend the edge up.
CAUTION:
Be careful not to damage tank. N
P
SLC930
CO-75
RADIATOR
< ON-VEHICLE REPAIR > [M9R]
3. Check the edge stands straight up.
SLC931
ASSEMBLY
1. Clean contact portion of tank.
SLC932
SLC917A
SLC904
CO-76
RADIATOR
< ON-VEHICLE REPAIR > [M9R]
CO
JPBIA0903ZZ
D
B. Keep tool perpendicular to the radiator C. Grip is insufficient
a. 90°
E
• Use pliers in the locations where radiator plate pliers A [SST:
KV99103510] cannot be used.
F
H
SLC897
SLC554A
L
5. Check that there is no leakage. Refer to CO-68, "Inspection".
Inspection INFOID:0000000001308727
M
INSPECTION AFTER INSTALLATION
• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-68, "Inspection". N
• Start and warm up the engine. Visually check that there is no leakage of engine coolant.
INSPECTION AFTER ASSEMBLY
O
1. Apply pressure with the radiator cap tester adapter (commercial
service tool) (A) and the radiator cap tester (commercial service
tool).
P
Testing pressure: Refer to CO-88, "Radiator".
WARNING:
To prevent the risk of hose coming undone while under
pressure, securely fasten it down with hose clamp.
JPBIA0736ZZ
CO-77
RADIATOR
< ON-VEHICLE REPAIR > [M9R]
2. Check for leakage by soaking radiator in water container with
the testing pressure applied.
SLC934
CO-78
COOLING FAN
< ON-VEHICLE REPAIR > [M9R]
COOLING FAN
A
Exploded View INFOID:0000000001308728
CO
I
JPBIA0793GB
REMOVAL M
1. Remove engine undercover.
2. Drain engine coolant from radiator. Refer to CO-68, "Draining".
CAUTION: N
Perform this step when the engine is cold.
3. Remove air duct (inlet). Refer to EM-263, "Exploded View".
4. Remove air inlet hose, air inlet pipe and bracket. Refer to EM-266, "Exploded View". O
5. Remove mounting bracket and mounting rubber (upper).
6. Disconnect harness connector from fan motors, and move harness to aside.
P
7. Disconnect radiator hose (upper).
8. Remove cooling fan assembly.
CAUTION:
Be careful not to damage radiator core when removing.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
CO-79
COOLING FAN
< ON-VEHICLE REPAIR > [M9R]
Only use genuine parts for fan shroud mounting bolt and observe the specified torque (to prevent
radiator from being damaged).
NOTE:
Cooling fan is controlled by ECM. For details, refer to ECR-284, "Description".
Disassembly and Assembly INFOID:0000000001308730
DISASSEMBLY
1. Remove cooling fan mounting nuts, and then remove the cooling fans (RH and LH).
2. Remove fan motors (RH and LH).
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
CAUTION:
RH and LH cooling fans are different. Be careful not to misassemble them.
• Install each fan in the following position.
CO-80
WATER PIPING
< ON-VEHICLE REPAIR > [M9R]
WATER PIPING
A
Exploded View INFOID:0000000001308735
CO
I
JPBIA0745GB
REMOVAL
1. Drain engine coolant from radiator. Refer to CO-68, "Draining". M
CAUTION:
Perform this step when engine is cold.
2. Disconnect water hoses and reservoir tank hose (lower).
N
CAUTION:
Never adhere the engine coolant to electronic equipments. (alternator etc.)
3. Remove EGR cooler tube. Refer to EM-268, "Exploded View".
O
4. Remove multifunction support bracket. Refer to EM-261, "Exploded View".
5. Remove water suction pipe.
• Engine coolant will leak from cylinder block, so have a receptacle ready below.
P
INSTALLATION
Note the following, and install in the reverse order of removal.
• When inserting water suction pipe end into cylinder block, apply a neutral detergent to O-ring. Then insert it
immediately.
CO-81
WATER PIPING
< ON-VEHICLE REPAIR > [M9R]
Inspection INFOID:0000000001308737
CO-82
WATER OUTLET AND THERMOSTAT ASSEMBLY
< ON-VEHICLE REPAIR > [M9R]
WATER OUTLET AND THERMOSTAT ASSEMBLY
A
Exploded View INFOID:0000000001308738
M/T models CO
JPBIA0749GB
K
1. Heater pipe 2. Clamp 3. Heater hose
4. Water outlet and thermostat assembly 5. Rubber ring 6. Bracket
L
7. Water pipe 8. Clamp 9. Water hose
10. Water hose 11. Heater hose 12. Heater pipe
13. Mounting bracket 14. Engine coolant temperature sensor 15. O-ring
M
16. Clip
A. To heater core B. To turbocharger C. To turbocharger cooling pump
D. To radiator E. To EGR cooler tube
N
Refer to GI-4, "Components" for symbols in the figure.
A/T models
O
CO-83
WATER OUTLET AND THERMOSTAT ASSEMBLY
< ON-VEHICLE REPAIR > [M9R]
JPBIA0748GB
REMOVAL
1. Drain engine coolant from radiator. Refer to CO-68, "Draining".
CAUTION:
Perform this step when engine is cold.
2. Remove battery. Refer to PG-133, "Exploded View".
3. Remove air duct assembly and air cleaner case. Refer to EM-263, "Exploded View".
4. Disconnect radiator hose (upper). Refer to CO-74, "Removal and Installation".
5. Disconnect harness connector from engine coolant temperature sensor.
6. Disconnect water hoses and heater hoses.
7. Remove heater pipes.
8. Remove water outlet and thermostat assembly.
9. Remove engine coolant temperature sensor from water outlet and thermostat assembly, if necessary.
CAUTION:
Handle carefully to avoid any shock to engine coolant temperature sensor.
CO-84
WATER OUTLET AND THERMOSTAT ASSEMBLY
< ON-VEHICLE REPAIR > [M9R]
INSTALLATION
Note the following, and install in the reverse order of removal. A
Water outlet and thermostat assembly
• Check that installation of the thermostat (1) and the rubber ring (2)
to the cylinder head. CO
JPBIA0750ZZ
E
Inspection INFOID:0000000001308740
Standard: I
Refer to CO-88, "Water Outlet and Thermostat Assem-
bly".
J
E1BIA0038ZZ
CO-85
WATER PUMP
< DISASSEMBLY AND ASSEMBLY > [M9R]
JPBIA0744GB
REMOVAL
1. Remove engine assembly. Refer to EM-312, "Exploded View".
NOTE:
Water pump cannot be removed with an onboard condition.
2. Remove water pump pulley.
3. Remove water pump.
• Loosen mounting bolts in reverse order as shown in the figure.
CAUTION:
• Handle water pump vane so that it does not contact any
other parts.
• Water pump cannot be disassembled and should be
replaced as a unit.
JPBIA0746ZZ
INSTALLATION
Note the following, and install in the reverse order of removal.
CO-86
WATER PUMP
< DISASSEMBLY AND ASSEMBLY > [M9R]
Water pump
• Tighten mounting bolts in numerical order as shown in the figure. A
• When inserting water pump end into cylinder block, apply a neutral
detergent to O-ring. Then insert it immediately.
CO
JPBIA0746ZZ D
Inspection INFOID:0000000001308734
E
INSPECTION AFTER REMOVAL
• Visually check if there is no significant dirt or rusting on water
pump body and vane (A).
• Check that there is no looseness in vane shaft, and that it turns F
smoothly when rotated by hand.
• Replace water pump, if necessary.
G
JPBIA0747ZZ
CO-87
SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [M9R]
Radiator INFOID:0000000001308742
RADIATOR
Unit: kPa (bar, kg/cm2, psi)
Standard
CO-88