ENGINE

ENGINE COOLING SYSTEM

SECTION CO CO

E
CONTENTS
HR12DE RADIATOR : Inspection ...........................................12 F

PRECAUTION ............................................... 2 REMOVAL AND INSTALLATION ............... 14

RADIATOR ........................................................ 14 G
PRECAUTIONS ................................................... 2
Precaution for Supplemental Restraint System Exploded View .........................................................14
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Removal and Installation .........................................14
SIONER" ................................................................... 2 Inspection ................................................................16 H
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect ..................................... 2
COOLING FAN .................................................. 17
Exploded View .........................................................17
I
PREPARATION ............................................ 4 Removal and Installation .........................................17
Disassembly and Assembly .....................................17
PREPARATION ................................................... 4 Inspection ................................................................18
Commercial Service Tools ....................................... 4 J
WATER PUMP .................................................. 19
SYSTEM DESCRIPTION .............................. 5 Exploded View .........................................................19
Removal and Installation .........................................19 K
DESCRIPTION .................................................... 5 Inspection ................................................................19
Engine Cooling System ............................................. 5
Engine Cooling System Schematic ........................... 6 THERMOSTAT .................................................. 21
Exploded View .........................................................21 L
SYMPTOM DIAGNOSIS ............................... 7 Removal and Installation .........................................21
Inspection ................................................................22
OVERHEATING CAUSE ANALYSIS .................. 7
M
Troubleshooting Chart ............................................... 7 WATER OUTLET .............................................. 23
Exploded View .........................................................23
PERIODIC MAINTENANCE .......................... 9 Removal and Installation .........................................24
Inspection ................................................................25 N
ENGINE COOLANT ............................................ 9
Inspection .................................................................. 9 SERVICE DATA AND SPECIFICATIONS
Draining ..................................................................... 9
(SDS) ............................................................ 26 O
Refilling ................................................................... 10
Flushing ................................................................... 11 SERVICE DATA AND SPECIFICATIONS
RADIATOR .........................................................12 (SDS) ................................................................. 26
Periodical Maintenance Specification ......................26 P
RADIATOR CAP ........................................................ 12 Radiator ...................................................................26
RADIATOR CAP : Inspection .................................. 12 Thermostat ..............................................................26
Water Control Valve ................................................26
RADIATOR ................................................................ 12

CO-1
 PRECAUTIONS
< PRECAUTION > [HR12DE]

PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000005988450

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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the “SRS AIR BAG” 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 that 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 AIR BAG”.
• 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.
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect
INFOID:0000000005988451

NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-
tion, then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the push-button ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.

CO-2
 PRECAUTIONS
< PRECAUTION > [HR12DE]
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering A
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT-III.
CO

CO-3
 PREPARATION
< PREPARATION > [HR12DE]

PREPARATION
PREPARATION
Commercial Service Tools INFOID:0000000005988452

Tool name Description

Radiator cap tester Checking radiator and radiator cap

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-4
 DESCRIPTION
< SYSTEM DESCRIPTION > [HR12DE]

SYSTEM DESCRIPTION A
DESCRIPTION
Engine Cooling System INFOID:0000000005988453
CO

WITH EGR CONTROL VALVE

C

JPBIA3438GB J
WITHOUT EGR CONTROL VALVE
K

JPBIA3439GB

CO-5
 DESCRIPTION
< SYSTEM DESCRIPTION > [HR12DE]
Engine Cooling System Schematic INFOID:0000000005988454

WITH EGR CONTROL VALVE

JPBIA3442GB

WITHOUT EGR CONTROL VALVE

JPBIA3441GB

CO-6
 OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [HR12DE]

SYMPTOM DIAGNOSIS A
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart INFOID:0000000005988455
CO

Symptom Check items

C
Water pump malfunction Worn or loose drive belt
Thermostat and water con-
—
trol valve stuck closed
D
Dust contamination or pa-
Poor heat transfer —
Damaged fins per clogging
Physical damage E
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Cooling fan does not oper- F
ate
Reduced air flow High resistance to fan rota- Fan assembly —
tion
G
Damaged fan blades
Damaged radiator shroud — — —

Cooling sys- Improper engine coolant H

— — —
tem parts mixture ratio
malfunction Poor engine coolant quality — Engine coolant viscosity —
Loose clamp I
Cooling hose
Cracked hose
Water pump Poor sealing
J
Loose
Radiator cap
Poor sealing
Engine coolant leakage
O-ring for damage, deterio- K
Insufficient engine coolant ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core L
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leakage into M
Overflowing reservoir tank Cylinder head gasket deteri-
cooling system
oration

CO-7
 OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [HR12DE]
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
Power train system mal-
function
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-8
 ENGINE COOLANT
< PERIODIC MAINTENANCE > [HR12DE]

PERIODIC MAINTENANCE A
ENGINE COOLANT
Inspection INFOID:0000000005988456
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

• Adjust the engine coolant level if necessary.

E

JPBIA0102ZZ
F
LEAKAGE
• To check for leakage, 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).

Testing pressure: Refer to CO-26, "Radiator". H

WARNING:
Never remove radiator cap when engine is hot. Serious burns
may occur from high-pressure engine coolant escaping from I
radiator.
CAUTION:
Higher test pressure than specified may cause radiator dam- PBIC5121J

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:0000000005988457

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. Open radiator drain plug (A) at the bottom of radiator, and then
remove radiator cap. N

: Vehicle front

CAUTION: O
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 EM.
P

JPBIA3336ZZ

2. Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing.
Refer to CO-14, "Exploded View".
3. Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to CO-11, "Flushing".

CO-9
 ENGINE COOLANT
< PERIODIC MAINTENANCE > [HR12DE]
Refilling INFOID:0000000005988458

1. Install reservoir tank if removed and radiator drain plug.

CAUTION:
Be sure to clean drain plug and install with new O-ring.

Radiator drain plug : Refer to CO-14, "Exploded View".

• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM.
2. Check that each hose clamp has been firmly tightened.
3. Remove air duct inlet and air cleaner assembly. Refer to EM-24, "Removal and Installation".
4. Disconnect heater hose (1) at position ( ) in the figure.

: Vehicle front

• Enhance heater hose as high as possible.

JPBIA3337ZZ

5. Fill radiator (1) to specified level.

CAUTION:
Never adhere the engine coolant to electronic equipments
(alternator etc.).
• Pour coolant slowly of less than 2 (2-1/8 US qt, 1-3/4
Imp 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.
• Use Genuine NISSAN Engine Coolant or equivalent in its
quality mixed with water (distilled or demineralized). Refer JPBIA0819ZZ
to MA-8, "Fluids and Lubricants".

Engine coolant capacity

(With reservoir tank at “MAX” level)
Refer to CO-26, "Periodical Maintenance Specifica-
tion".

6. Refill reservoir tank to “MAX” level line with engine coolant.

A : MAX
B : MIN

Reservoir tank engine coolant capacity

(At “MAX” level)
Refer to CO-26, "Periodical Maintenance Specification".

JPBIA0102ZZ

7. Install air duct (between air cleaner case and electric throttle control actuator). Refer to EM-24, "Removal
and Installation".
8. Install radiator cap.
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 (lower) to see a flow of warm water.

CO-10
 ENGINE COOLANT
< PERIODIC MAINTENANCE > [HR12DE]
CAUTION:
Watch water temperature gauge so as not to overheat engine. A
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. CO
CAUTION:
Never adhere the engine coolant to electronic equipments (alternator etc.).
11. Refill reservoir tank to “MAX” level line with engine coolant.
C
12. Repeat steps 5 through 10 two or more times with radiator cap installed until engine coolant level no
longer drops.
13. Check cooling system for leakage with engine running. D
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.
E
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.
F
Flushing INFOID:0000000005988459

1. Install reservoir tank if removed and radiator drain plug. G

CAUTION:
Be sure to clean drain plug and install with new O-ring.
H
Radiator drain plug : Refer to CO-14, "Exploded View".
• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM.
2. Remove air duct inlet and air cleaner case assembly. Refer to EM-24, "Removal and Installation". I
3. Disconnect heater hose (1) at position ( ) in the figure.

: Vehicle front J
• Enhance heater as high as possible.

L
JPBIA3337ZZ

4. Fill radiator and reservoir tank with water and reinstall radiator cap. M
• When engine coolant over flows disconnected heater hose, connect heater hose, and continue filling the
engine coolant.
5. Install air duct (between air cleaner case and electric throttle control actuator). Refer to EM-24, "Removal N
and Installation".
6. Run the engine and warm it up to normal operating temperature.
7. Rev the engine two or three times under no-load. O
8. Stop the engine and wait until it cools down.
9. Drain water from the system. Refer to CO-9, "Draining".
10. Repeat steps 1 through 9 until clear water begins to drain from radiator. P

CO-11
 RADIATOR
< PERIODIC MAINTENANCE > [HR12DE]
RADIATOR
RADIATOR CAP
RADIATOR CAP : Inspection INFOID:0000000005988460

• Check valve seat (A) of radiator cap.

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

• Pull negative-pressure valve to open it, and that it close completely

when released.
- 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
conditions of negative-pressure valve.

SMA967B

• Check radiator cap relief pressure.

Standard and Limit : Refer to CO-26, "Radiator".

- When connecting radiator cap to the radiator cap tester (commer-
cial service tool) (A) and the radiator cap tester adapter (commer-
cial service tool) (B), apply engine coolant to the cap seal surface.

PBIC5122J

• 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
or foreign material.
RADIATOR
RADIATOR : Inspection INFOID:0000000005988461

Check radiator for mud or clogging. If necessary, clean radiator as follows.

CAUTION:
• Be careful not to bend or damage radiator fins.
• When radiator is cleaned without removal, remove all surrounding parts such as radiator cooling fan
assembly and horns. Then tape harness and harness connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing if any stains no longer flow out from radiator.

CO-12
 RADIATOR
< PERIODIC MAINTENANCE > [HR12DE]
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
(11.81 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
CO

CO-13
 RADIATOR
< REMOVAL AND INSTALLATION > [HR12DE]

REMOVAL AND INSTALLATION

RADIATOR
Exploded View INFOID:0000000005988462

JPBIA3390GB

1. Reservoir tank cap 2. Reservoir tank 3. Reservoir tank hose

4. Radiator cap 5. Mounting rubber (upper) 6. Radiator
7. Mounting rubber (lower) 8. Clamp 9. A/T fluid hose
10. Clamp 11. Radiator hose (upper) 12. Radiator hose (lower)
13. Fan shroud assembly
A. To water outlet B. To water inlet C. M/T models
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000005988463

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. Drain engine coolant from radiator. Refer to CO-9, "Draining".
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.
2. Remove air duct (inlet). Refer to EM-24, "Removal and Installation".

CO-14
 RADIATOR
< REMOVAL AND INSTALLATION > [HR12DE]
3. Disconnect reservoir tank hose, and remove reservoir tank.
4. Disconnect harness connector from fan motor, and move harness aside. A
5. Remove radiator hose (upper and lower).
6. Remove cooling fan assembly.
CAUTION: CO
Be careful not to damage or scratch the radiator core.
7. Remove front bumper fasica assembly. Refer to EXT-11, "Removal and Installation".
8. Remove radiator core support (upper). Refer to DLK-114, "Removal and Installation" (With Intelligent Key) C
or DLK-219, "Removal and Installation" (Without Intelligent Key).
9. Remove the radiator (1) from bottom of the vehicle.
D
2 : Condenser assembly
: Vehicle front
E
CAUTION:
Be careful not to damage radiator core and condenser
assembly core.
F

JPBIA3425ZZ
G
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
H
• Replace water hose clamp if it is removed.
• Use genuine mounting bolts for the cooling fan assembly and strictly observe the tightening torque.
(Breakage prevention for radiator)
NOTE: I
• Insert the radiator hose (1) all the way to the stopper (2) or by 33 mm (1.30in) (hose without a stopper)

JSBIA0238GB

Unit mm (in)
M
A. Radiator side B. Engine side

• For the orientation of the hose clamp pawl, refer to the figure. N

Radiator hose Hose end Paint mark Position of hose clamp*

Radiator side Upper A O
Radiator hose (upper)
Engine side Upper B
Radiator side Lower C
Radiator hose (lower)
Engine side Upper D P
*Refer to the illustrations for the specific position each hose clamp tab.

CO-15
 RADIATOR
< REMOVAL AND INSTALLATION > [HR12DE]

JPBIA3203ZZ

a. 45°
Vehicle upper

• The angle (a) created by the hose clamp pawl and the specified
line (A) must be within ±30° as shown in the figure.

JSBIA0240ZZ

• To install hose clamps (1), check that the dimension (A) from the
end of the hose clamp (1) on the radiator hose to the hose clamp is
within the reference value.

Dimension “A” (+3) – (+7)mm

JPBIA3527ZZ

Inspection INFOID:0000000005988464

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-9, "Inspection".
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.

CO-16
 COOLING FAN
< REMOVAL AND INSTALLATION > [HR12DE]
COOLING FAN
A
Exploded View INFOID:0000000005988465

CO

G
JPBIA3464GB

1. Cooling fan 2. Fan motor 3. Fan shroud

A. Apply on fan motor shaft
H
: Apply genuine high strength thread locking sealant or equivalent.

Refer to GI-4, "Components" for symbols not described on the above.

I
Removal and Installation INFOID:0000000005988466

REMOVAL J

1. Drain engine coolant from radiator. Refer to CO-9, "Draining".

CAUTION:
• Perform this step engine is cold. K
• Never spill engine coolant on drive belt.
2. Remove air duct (inlet). Refer to EM-24, "Removal and Installation".
3. Disconnect reservoir tank hose radiator side, and remove reservoir tank. L
4. Remove radiator hose (upper). Refer to CO-14, "Exploded View".
5. Disconnect harness connector from fan motor, and move harness to aside.
M
6. Remove cooling fan assembly.
CAUTION:
Be careful not to damage or scratch on radiator core when removing.
N
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Only use genuine parts for fan shroud mounting bolt and observe the specified torque (to prevent O
radiator from being damaged).
NOTE:
Cooling fan is controlled by ECM. For details, Refer to following. P
• HR12DE (TYPE 1): EC-38, "COOLING FAN CONTROL : System Description"
• HR12DE (TYPE 2): EC-343, "COOLING FAN CONTROL : System Description"
Disassembly and Assembly INFOID:0000000005988467

DISASSEMBLY
1. Remove cooling fan mounting nut, and then remove the cooling fan.

CO-17
 COOLING FAN
< REMOVAL AND INSTALLATION > [HR12DE]
2. Remove fan motor.
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
• Apply genuine high strength thread locking sealant on fan motor shaft.
Inspection INFOID:0000000005988468

INSPECTION AFTER DISASSEMBLY

Cooling Fan
Inspect cooling fan for crack or unusual bend.
• If anything is found, replace cooling fan.

CO-18
 WATER PUMP
< REMOVAL AND INSTALLATION > [HR12DE]
WATER PUMP
A
Exploded View INFOID:0000000005988469

CO

G
PBIC3807E

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

Refer to GI-4, "Components" for symbols in the figure.
H

Removal and Installation INFOID:0000000005988470

I
REMOVAL
1. Drain engine coolant from radiator. Refer to CO-9, "Draining".
CAUTION: J
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.
2. Steer front wheel to the right. K
3. Remove front fender protector (RH). Refer to DLK-221, "Removal and Installation".
4. Loosen mounting bolts of water pump pulley before loosening belt tension of drive belt.
5. Remove drive belt. Refer to EM-19, "Removal and Installation". L
6. Remove water pump pulley.
7. Remove water pump.
• Loosen mounting bolts in reverse order as shown in the figure. M
• Engine coolant will leak from cylinder block, so have a recep-
tacle ready below.
CAUTION: N
• 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. O

KBIA3393J
P

INSTALLATION
Install in the reverse order of removal.
Inspection INFOID:0000000005988471

INSPECTION AFTER REMOVAL

CO-19
 WATER PUMP
< REMOVAL AND INSTALLATION > [HR12DE]
• Check visually that 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
smoothly when rotated by hand.
• Replace water pump, if necessary.

PBIC3313J

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-9, "Inspection".
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.

CO-20
 THERMOSTAT
< REMOVAL AND INSTALLATION > [HR12DE]
THERMOSTAT
A
Exploded View INFOID:0000000005988472

CO

G
JPBIA3387GB

1. Water inlet 2. Rubber ring 3. Thermostat

A. To radiator
H
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000005988473 I

REMOVAL
1. Drain engine coolant from radiator. Refer to CO-9, "Draining". J
CAUTION:
Perform this step when engine is cold.
2. Remove air duct (inlet). Refer to EM-24, "Removal and Installation". K
3. Disconnect radiator hose (lower) from water inlet. Refer to CO-14, "Removal and Installation".
4. Remove water inlet and thermostat.
• Engine coolant leakage from cylinder block, so have a receptacle ready below. L
INSTALLATION
Note the following, and install in the reverse order of removal.
M
Thermostat
• Install thermostat with making rubber ring (1) groove fit to thermo-
stat flange (A) with the whole circumference.
N

PBIC3315J

CO-21
 THERMOSTAT
< REMOVAL AND INSTALLATION > [HR12DE]
• Install thermostat (2) with jiggle valve (A) facing upwards.

1 : Cylinder block

PBIC3812E

Water Inlet
After installation, install oil level gauge guide (1) as shown in the fig-
ure.

2 : Water inlet

JPBIA3426GB

Inspection INFOID:0000000005988474

INSPECTION AFTER REMOVAL

Thermostat
• Place a thread (A) so that it is caught in the valves of thermostat
(1). Immerse fully in a container (B) filled with water. Heat while
stirring.
• The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
• Continue heating. Check the full open valve lift amount.
• After checking the maximum valve lift amount, lower the water
temperature and check the valve closing temperature.

Standard: Refer to CO-26, "Thermostat".

• If out of the standard, replace thermostat. PBIC3314J

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-9, "Inspection".
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.

CO-22
 WATER OUTLET
< REMOVAL AND INSTALLATION > [HR12DE]
WATER OUTLET
A
Exploded View INFOID:0000000005988475

WITHOUT EGR CONTROL VALVE CO

JPBIA3465GB

1. Gasket 2. Engine coolant temperature sensor 3. O-ring K

4. EGR control valve 5. EGR temp sensor 6. Water outlet

L
A. To heater B. To radiator
: Engine front
Refer to GI-4, "Components" for symbols in the figure.
M

CO-23
 WATER OUTLET
< REMOVAL AND INSTALLATION > [HR12DE]
WITH EGR CONTROL VALVE

JPBIA3389GB

1. Engine coolant temperature sensor 2. Washer 3. Gasket

4. Radiator hose (upper) 5. Water outlet 6. Heater hose
7. Heater hose
A. To heater B. To radiator
: Engine front
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000005988476

REMOVAL
1. Drain engine coolant from radiator. Refer to CO-9, "Draining".
CAUTION:
• Perform this step when engine is cold.
2. Remove air duct (inlet) and air cleaner assembly. Refer to EM-24, "Removal and Installation".
3. Disconnect radiator hose (upper). Refer to CO-14, "Removal and Installation".
4. Disconnect harness connector from engine coolant temperature sensor.
5. Disconnect harness connector from EGR control valve and EGR temp sensor. (With EGR control valve)
6. Remove water hoses and heater hoses.
7. Remove water outlet.
8. Remove engine coolant temperature sensor from water outlet, if necessary.
INSTALLATION
Installation is the reverse order of removal.

CO-24
 WATER OUTLET
< REMOVAL AND INSTALLATION > [HR12DE]
Inspection INFOID:0000000005988477

A
INSPECTION AFTER REMOVAL
Water Control Valve
CO
• Place a thread (A) so that it is caught in the valves of water control
valve (1). Immerse fully in a container (B) filled with water. Heat
while stirring.
• The valve opening temperature is the temperature at which the C
valve opens and falls from the thread.
• Continue heating. Check the continuous valve lifting toward maxi-
mum valve lift. D
NOTE:
The maximum valve lift amount standard temperature for water
control valve is the reference value.
• After checking the maximum valve lift amount, lower the water E
PBIC3314J
temperature and check the valve closing temperature.

Standard: Refer to CO-26, "Water Control Valve". F

• If out of the standard, replace water control valve.
INSPECTION AFTER INSTALLATION G
• 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-9, "Inspection".
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.
H

CO-25
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR12DE]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)
Periodical Maintenance Specification INFOID:0000000005988478

ENGINE COOLANT CAPACITY (APPROXIMATE)

Unit: (US qt, Imp qt)

A/T models
Engine coolant capacity (With reservoir tank at “MAX” level) M/T models (without EGR control 5.5 (5-6/8, 4-7/8)
valve)
M/T models (with EGR control valve) 5.7 (6, 5)
Reservoir tank engine coolant capacity (At “MAX” level) 0.7 (3/4, 5/8)

Radiator INFOID:0000000005988479

Unit: kPa (kg/cm2, psi)

Standard 78 - 98 (0.8 - 1.0, 11 - 14)

Cap relief pressure
Limit 59 (0.6, 9)
Leakage testing pressure 98 (1.0, 14)

Thermostat INFOID:0000000005988480

Standard

Valve opening temperature 80.5 - 83.5°C (177 - 182°F)

Maximum valve lift 8.0 mm/95°C (0.315 in/203°F)
Valve closing temperature 77°C (171°F)

Water Control Valve INFOID:0000000005988481

Standard

Valve opening temperature 93.5 - 96.5°C (200 - 206°F)

Maximum valve lift 8.0 mm/108°C (0.315 in/226°F)
Valve closing temperature 90°C (194°F)

CO-26