ENGINE

ENGINE COOLING SYSTEM

SECTION CO CO

E
CONTENTS
ZD Changing Engine Coolant ......................................... 7 F

SERVICE INFORMATION ............................ 2 RADIATOR ........................................................ 10

Component ..............................................................10
G
PRECAUTIONS ................................................... 2 Removal and Installation .........................................10
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- COOLING FAN .................................................. 13
SIONER" ................................................................... 2 Component ..............................................................13 H
Removal and Installation .........................................13
PREPARATION ................................................... 3
Special Service Tool ................................................. 3 WATER PUMP .................................................. 14
Component ..............................................................14 I
Commercial Service Tool .......................................... 3
Removal and Installation .........................................14
OVERHEATING CAUSE ANALYSIS .................. 4
Troubleshooting Chart ............................................... 4 THERMOSTAT AND WATER PIPING .............. 16 J
Component ..............................................................16
COOLING SYSTEM ............................................ 6 Removal and Installation .........................................16
Cooling Circuit ........................................................... 6
SERVICE DATA AND SPECIFICATIONS K
ENGINE COOLANT ............................................ 7 (SDS) ................................................................. 18
Inspection .................................................................. 7 Standard and Limit ..................................................18
L

CO-1
 PRECAUTIONS
< SERVICE INFORMATION > [ZD]

SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000005198449

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 “SUPPLEMENTAL
RESTRAINT SYSTEM” and “SEAT BELTS” 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 “SUPPLEMENTAL RESTRAINT SYSTEM”.
• 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.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.

CO-2
 PREPARATION
< SERVICE INFORMATION > [ZD]
PREPARATION
A
Special Service Tool INFOID:0000000004943433

CO
Tool number
Description
Tool name
EG17650301 Adapts radiator cap tester to radiator cap and
C
Radiator cap tester adapter radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia. D
Unit: mm (in)

S-NT564
E
KV99103510 Installs radiator upper and lower tanks
Radiator plate pliers A

G
S-NT224

KV99103520 Removes radiator upper and lower tanks

Radiator plate pliers B H

S-NT225

J
Commercial Service Tool INFOID:0000000004943434

Tool name Description K

Radiator cap tester Checks radiator and reservoir tank cap

M
PBIC1982E

CO-3
 OVERHEATING CAUSE ANALYSIS
< SERVICE INFORMATION > [ZD]
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart INFOID:0000000004943435

Symptom Check items

Water pump malfunction Worn or loose drive belt
Thermostat stuck closed —
Dust contamination or pa-
Poor heat transfer Damaged fins per clogging —
Physical damage
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Cooling fan does not oper- Refer to EC-110, "DTC Log-
ate ic"
Reduced air flow High resistance to fan rota- —
tion Fan assembly
Damaged fan blades
Damaged radiator shroud — — —
Improper engine coolant
Cooling sys- — — —
mixture ratio
tem parts
malfunction Poor engine coolant quality — Engine coolant density —
Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Loose
Radiator cap
Poor sealing
Engine coolant leakage
O-ring for damage, deterio-
Insufficient engine coolant ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leakage into
Overflowing reservoir tank Cylinder head gasket deteri-
cooling system
oration

CO-4
 OVERHEATING CAUSE ANALYSIS
< SERVICE INFORMATION > [ZD]
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
Powertrain system malfunc-
tion
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-5
 COOLING SYSTEM
< SERVICE INFORMATION > [ZD]
COOLING SYSTEM
Cooling Circuit INFOID:0000000004943436

JPBIA2932GB

CO-6
 ENGINE COOLANT
< SERVICE INFORMATION > [ZD]
ENGINE COOLANT
A
Inspection INFOID:0000000004943437

LEVEL CHECK CO
• Check that the reservoir tank engine coolant level within MIN to
MAX when engine is cool.
• Fill withill engine coolant if necessary, according to the refilling pro- C
cedure as described later in this section. Refer to CO-7, "Changing
Engine Coolant".
D

E
MBIB9103E

CHECKING RADIATOR SYSTEM FOR LEAKAGE

• To check for leakage of cooling system, apply pressure to the reservoir tank with the radiator cap tester F
(commercial service tool) and the radiator cap tester adapter [SST: EG17650301].
WARNING:
Never remove reservoir tank cap and/or radiator cap when engine is hot. Serious burns could occur G
from high pressure engine coolant escaping from reservoir tank and/or radiator.
CAUTION:
• Never install radiator cap tester (commercial service tool) and the radiator cap tester adapter [SST: H
EG17650301] to radiator.
• Higher test pressure than specified may cause cooling system damage.
I
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
NOTE: J
In a case that engine coolant decreases, replenish radiator and reservoir tank with engine coolant.
• If anything is found, repair or replace damaged parts.
Changing Engine Coolant INFOID:0000000004943438
K

WARNING:
• To avoid being scalded, never change engine coolant when engine is hot. L
• Wrap a thick cloth around cap and carefully remove cap. First, turn cap a quarter of a turn to release
built-up pressure. Then turn cap all the way.
• Be careful not to allow engine coolant to contact drive belts. M
DRAINING ENGINE COOLANT
1. Remove drain plug from the bottom of radiator, and then remove
radiator cap. N

JSKIA1217ZZ

CO-7
 ENGINE COOLANT
< SERVICE INFORMATION > [ZD]
2. Open cylinder block drain plug. Refer to EM-90.
3. Remove reservoir tank, drain engine coolant, then clean reser-
voir tank.
4. Check drained engine coolant for contaminants such as rust,
corrosion or discoloration.
If contaminated, flush engine cooling system. Refer to "FLUSH-
ING COOLING SYSTEM".

MBIB9105E

REFILLING ENGINE COOLANT

1. Install reservoir tank and radiator drain plug.
• If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-90, "Disassem-
bly and Assembly".
2. Check that each hose clamp is firmly tightened.
3. Fill radiator and reservoir tank to the specified level.
• Pour engine coolant through engine coolant filler neck
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.
• Use Genuine NISSAN Engine Coolant or an equivalent in
its quality. Refer to MA-9.

Engine coolant capacity

(with reservoir tank at “MAX” level)
: Approx. 12.7 (11-1/8 lmp qt)
SMA182B

Reservoir tank capacity (at “MAX” level)

: 1.0 (1/2 lmp qt)
• When engine coolant overflows air relief hole, install air relief
plug and install the radiator cap.

MBIB9103E

4. Start engine and warm it up until it reaches normal operating temperature (10 min maximum).
• If engine coolant overflows radiator filler hole, install radiator cap.
5. Keep racing at 2,000 - 2,500 rpm and fill with through reservoir tank filler until water level stabilize on
MAX. Close reservoir tank cap and continue warm up until thermostat is opened (check the radiator
hose).
CAUTION:
Watch engine coolant temperature gauge so as not to overheat the engine.
6. Keep racing at 2,000 - 2,500 rpm and fill with through reservoir tank filler until water level stabilize on
MAX. Close reservoir tank cap and continue warm up until thermostat is opened (check the radiator
hose). At this time, the water temperature must not rise excessively.
7. Stop the engine and cool down to less than approximately 50° (122°F).
8. Fill with reservoir tank to MAX level line with engine coolant.
9. If the liquid level lowered, repeat steps 4 through 8 checking that water level on reservoir tank is stabilized
on MAX.
10. Check cooling system for leakage with engine running.

CO-8
 ENGINE COOLANT
< SERVICE INFORMATION > [ZD]
11. 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 position between COOL and WARM. A
• Sound may be noticeable at heater unit.
12. Repeat step 11 three times.
13. If sound is heard, bleed air from cooling system by repeating steps 3 through 6 until engine coolant level CO
no longer drops.
FLUSHING COOLING SYSTEM
C
1. 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 and reservoir tank cap.
2. Run engine and warm it up to normal operating temperature.
D
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down.
5. Drain water from the system. Refer to "DRAINING ENGINE COOLANT". E
6. Repeat steps 1 through 5 until clear water begins to drain from radiator.

CO-9
 RADIATOR
< SERVICE INFORMATION > [ZD]
RADIATOR
Component INFOID:0000000004943439

JPBIA2933GB

1. Radiator 2. Rubber mounting 3. Radiator mounting bracket RH

4. Washer 5. Air guide bracket 6. Air guide
7. Radiator mounting bracket LH 8. Baffle plate LH 9. Reservoir tank hose (OUT)
10. Radiator hose lower 11. Radiator stay LH 12. Reservoir tank
13. Reservoir tank cap 14. Reservoir tank hose (IN) 15. Radiator cap
16. Radiator hose upper 17. Radiator stay RH

• Refer to GI-8, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000004943440

WARNING:
Never remove radiator cap and/or reservoir tank cap when engine is hot. Serious burns could occur
from high-pressure engine coolant escaping from radiator and/or reservoir tank.

CO-10
 RADIATOR
< SERVICE INFORMATION > [ZD]
REMOVAL
1. For double cab models, remove engines covers. Refer to EM-10, "Component (Double Cab Only)". A
2. Drain engine coolant from radiator. Refer to CO-7, "Changing Engine Coolant".
CAUTION:
Perform this step when engine is cold. CO
Never spill engine coolant on drive belts.
3. Remove air inlet hoses between engine to charge air cooler. Refer to EM-17.
4. Disconnect radiator hose (upper and lower) and reservoir tank hose. C
CAUTION:
Be careful not to allow engine coolant to contact drive belts.
5. For double cab models, remove: D
• Remove reservoir tank.
• Remove cooling fans (crankshaft driven type radiator shrouds upper and lower). Refer to CO-13.
• Radiator hoses. E
• Charge air cooler hoses.
6. Remove mounting nuts securing the radiator to mounting brackets.
7. Remove radiator stay mounting bolts on the suspension member. F
8. Remove radiator.
CAUTION:
Never damage radiator core when removing.
G
INSPECTION AFTER REMOVAL
Checking Reservoir Tank Cap
• Inspect valve seat of reservoir tank cap. H
- 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. I

PBIC2816E
K

• Pull negative-pressure valve to open it, and make sure that it is

completely closed when released. L
- Check that there is no dirt or damage on the valve seat of radiator
cap negative-pressure valve.
- Check that there are no unusualness in the opening and closing M
conditions of negative-pressure valve.

SMA967B
O

CO-11
 RADIATOR
< SERVICE INFORMATION > [ZD]
• Check reservoir tank cap relief pressure.

Standard : 78.4 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0

kg/cm2, 11 - 14 psi)
Limit : 78.4 kPa (0.78 bar, 0.8 kg/cm2, 11 psi)
- When connecting reservoir tank cap to the radiator cap tester
adapter (SST) and the radiator cap tester (Commercial service
tool), apply engine coolant to the cap seal surface.

SLC755AC

• Replace reservoir tank cap if there is an unusualness in negative pressure valve, or if the relief pressure falls
below the limit.
CAUTION:
When installing a radiator cap and reservoir tank cap, thoroughly wipe out the radiator and reservoir
tank filler neck to remove any waxy residue or foreign material.
Checking Radiator
Check radiator for mud or clogging. If necessary, clean radiator as per the following items.
• Be careful not to bend or damage the radiator fins.
• When radiator is cleaned without removal, remove all surrounding 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 vertically downwards.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downwards.
• 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 surface once per minute until no water sprays out.
INSTALLATION
Installation is the reverse order of removal.
INSPECTION AFTER INSTALLATION
• Check for leakage of engine coolant using the radiator cap tester adapter [SST: EG17650301] and the radi-
ator cap tester (commercial service tool). Refer to CO-7, "Inspection".
• Start and warm up engine. Visually check that there is no leakage of engine coolant.

CO-12
 COOLING FAN
< SERVICE INFORMATION > [ZD]
COOLING FAN
A
Component INFOID:0000000004943441

CO

G
PBIC4875E

1. Cooling fan 2. Fan coupling 3. Water pump pulley

4. Water pump
H
A. Front mark “F”

Removal and Installation INFOID:0000000004943442 I

REMOVAL
1. Remove drive belts. Refer to EM-12, "Checking Drive Belt". J
2. Loosen and remove radiator shroud (upper) mounting bolts. Refer to CO-10.
3. Move radiator shroud (upper) toward engine, and remove cooling fan (crankshaft driven type).
CAUTION: K
Be careful not to damage or scratch on radiator core.
4. Remove fan coupling and water pump pulley.
L
INSPECTION AFTER REMOVAL
Fan Coupling
Check fan coupling for rough operation, wobbling, oil leakage or bent M
bimetal.

SLC072 P
INSTALLATION
Installation is the reverse order of removal.
• Install cooling fan with its front mark “F” facing front of engine.

CO-13
 WATER PUMP
< SERVICE INFORMATION > [ZD]
WATER PUMP
Component INFOID:0000000004943443

JPBIA2960GB

1. Gasket 2. Water pump 3. Water pump pulley

4. Gear case 5. Water inlet 6. Rubber ring
7. Thermostat

• Refer to GI-8, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000004943444

WARNING:
Never remove radiator cap and/or reservoir tank cap when the engine is hot. Serious burns could
occur from high pressure engine coolant escaping from the radiator and/or the reservoir tank.
CAUTION:
• When removing water pump assembly, be careful not to get engine coolant on drive belts.
• Water pump cannot be disassembled and should be replaced as a unit.
• After installing water pump, connect hose and clamp securely, then check for leakage using radiaor
cap tester (commercial service tool) and radiator cap tester adapter [SST: EG17650301].
REMOVAL
1. Drain engine coolant up to the level where no engine coolant spills from water pump. Refer to CO-7,
"Changing Engine Coolant".
CAUTION:
• Perform this step when engine is cold.
• Never spill engine coolant on drive belts.
2. Remove drive belt. Refer to EM-12.
3. Remove water pump pulley.

CO-14
 WATER PUMP
< SERVICE INFORMATION > [ZD]
4. Remove mounting bolts and nuts (A to E) shown in figure.
Remove water pump. There is engine coolant leakage from cylinder A
block, so have a receptacle ready below.
CAUTION:
• Be careful not to drop water inlet and thermostat as water
CO
inlet is tighten bolts E.
• Water pump cannot be disassembled and should be replaced
as a unit.
C

MBIB9149E

D
INSPECTION AFTER REMOVAL
• Visually check that there is no significant dirt or rusting on the
water pump body and vane.
• Check that there is no looseness in the vane shaft, and that it turns E
smoothly when rotated by hand.
• If there are any unusualness, replace water pump assembly as
necessary. F

PBIC3354E

INSTALLATION H
Note the following, and install in the reverse order of removal.
Water Pump
• Bolts and nuts vary depending on installation location. Refer to CO-14, "Component". I
• If threads of bolts E are difficult to engage, move water inlet to adjust thread position.

Bolt length: J
A : — (Nut)
B : 30 mm (1.18 in)
C : 50 mm (1.97 in) K
D : 60 mm (2.36 in)
E : 90 mm (3.54 in) L
• Install cooling fan with the front mark "F" facing the front of engine. Refer to CO-13.
INSPECTION AFTER INSTALLATION
• Check for leakage of engine coolant using the radiator cap tester adapter [SST: EG17650301] and the radi- M
ator cap tester (commercial service tool). Refer to CO-7, "Inspection".
• Start and warm up engine. Visually check that there is no leakage of engine coolant.
N

CO-15
 THERMOSTAT AND WATER PIPING
< SERVICE INFORMATION > [ZD]
THERMOSTAT AND WATER PIPING
Component INFOID:0000000004943445

JPBIA2961GB

1. Water pipe 2. Engine coolant temperature sensor 3. O-ring

4. Water connector 5. Water hose 6. Water outlet
7. Gasket 8. Water pipe 9. Gasket
10. Water inlet 11. Water connector 12. Thermostat
13. Water pipe

• Refer to GI-8, "Component" for symbol marks in the figure.

Removal and Installation INFOID:0000000004943446

WARNING:
Never remove radiator cap and/or reservoir tank cap when engine is hot. Serious burns could occur
from high pressure engine coolant escaping from radiator and/or reservoir tank.
REMOVAL
1. Drain engine coolant. Refer to CO-7, "Changing Engine Coolant".
CAUTION:
Perform when the engine is cold.
2. Remove drive belt. Refer to EM-12.
3. Remove alternator. Refer to SC-17, "Removal and Installation".
4. Remove water inlet and water outlet.
5. Remove thermostat.
6. Remove water pipe. Refer to EM-19.

CO-16
 THERMOSTAT AND WATER PIPING
< SERVICE INFORMATION > [ZD]
INSPECTION AFTER REMOVAL
A
Thermostat
• Place a string so that it is caught in the valves of the thermostat.
Immerse fully in a container filled with water. Heat while stirring.
• The valve opening temperature is the temperature at which the CO
valve opens and falls from the thread.
• Continue heating. Check the full-open lift amount.
• After checking the full-open lift amount, lower the water tempera- C
ture and check the valve closing temperature.

SLC252B

Standard values E
Items Thermostat
Valve opening temperature 80.0 - 84°C (176 - 183° F)
Full-open lift amount More than 9 mm/95°C (0.35 in/203 °F) F
Valve closing temperature More than 77°C (171°F)
• If out of the standard, replace thermostat.
G
INSTALLATION
Note the following, and install in the reverse order of removal.
• Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge. H
• When inserting heater feed pipe end into cylinder head, apply a neutral detergent to O-ring. Then insert it
immediately.
• Install the thermostat with the whole circumference of each flange
part fit securely inside the rubber ring. I
• Install the thermostat with the jiggle valve facing upwards.

JLC300B
L
INSPECTION AFTER INSTALLATION
• Check for leakage of engine coolant using the radiator cap tester adapter [SST: EG17650301] and the radi-
ator cap tester (commercial service tool). Refer to CO-7, "Inspection".
• Start and warm up engine. Visually check that there is no leakage of engine coolant. M

CO-17
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [ZD]
SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit INFOID:0000000004943447

ENGINE COOLANT CAPACITY

Unit: (lmp qt)

Engine coolant capacity

Approx 12.7 (11-1/8)
(With reservoir tank at “MAX” level)
Reservoir tank 1.0 (7/8)

THERMOSTAT

Valve opening temperature 80.0 - 84°C (176 - 183°F)

Full open lift amount More than 9 mm/95°C (0.35 in/203°F)
Valve closing temperature More than 77°C (171°F)

RESERVOIR TANK
Unit: kPa (bar, kg/cm2, psi)

Standard 78.4 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)

Cap relief pressure
Limit 78.4 (0.78, 0.8, 11)
Leakage test pressure 157 (1.57, 1.6, 23)

CO-18