Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Nissan Frontier 2003-2005 Approved Nissan Frontier 2005 CO
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B ENGINE
A
ENGINE COOLING SYSTEM
SECTION CO CO
C
D
E
CONTENTS
QR WATER PUMP ......................................................... 15. F
Removal and Installation ....................................... 15 .
PRECAUTIONS ......................................................... 3
. REMOVAL .......................................................... 15
.
Precautions for Liquid Gasket ................................. 3 . INSPECTION AFTER REMOVAL ...................... 16 . G
REMOVAL OF LIQUID GASKET SEALING ......... 3 . INSTALLATION .................................................. 16 .
LIQUID GASKET APPLICATION PROCEDURE 3 ..... INSPECTION AFTER INSTALLATION ............... 16 .
PREPARATION .......................................................... 4
. THERMOSTAT AND THERMOSTAT HOUSING ..... 17 .
Special Service Tools .............................................. 4
. H
Removal and Installation Thermostat .................... 17 .
Commercial Service Tools ....................................... 4 . REMOVAL .......................................................... 17
.
OVERHEATING CAUSE ANALYSIS ......................... 5 . INSPECTION AFTER REMOVAL ...................... 17 .
Troubleshooting Chart ............................................. 5
. INSTALLATION .................................................. 18 . I
COOLING SYSTEM ................................................... 7 . INSPECTION AFTER INSTALLATION ............... 18 .
Cooling Circuit ......................................................... 7
. Removal and Installation Water Pump and Ther-
System Chart .......................................................... 8
. mostat Housing ...................................................... 19
. J
ENGINE COOLANT ................................................... 9 . REMOVAL .......................................................... 19
.
System Check ......................................................... 9
. INSTALLATION .................................................. 19 .
CHECKING COOLING SYSTEM HOSES ........... 9 . INSPECTION AFTER INSTALLATION ............... 19 .
CHECKING RESERVOIR LEVEL ........................ 9 . K
WATER CONTROL VALVE ...................................... 21 .
CHECKING COOLING SYSTEM FOR LEAKS ..... 9 Removal and Installation ....................................... 21 .
CHECKING RESERVOIR CAP ............................ 9 . REMOVAL .......................................................... 21
.
CHECKING RADIATOR ..................................... 10 . INSPECTION AFTER REMOVAL ...................... 22 . L
Changing Engine Coolant ..................................... 10 . INSTALLATION .................................................. 22 .
DRAINING ENGINE COOLANT ........................ 10 . WATER OUTLET AND WATER PIPING .................. 23 .
REFILLING ENGINE COOLANT ....................... 10 . Removal and Installation ....................................... 23 . M
FLUSHING COOLING SYSTEM ........................ 10 . REMOVAL .......................................................... 23
.
RADIATOR ................................................................11
. INSTALLATION .................................................. 23 .
Removal and Installation ........................................11 . INSPECTION AFTER INSTALLATION ............... 24 .
REMOVAL ...........................................................11
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 25 .
INSTALLATION .................................................. 13. Standard and Limit ................................................. 25
.
INSPECTION AFTER INSTALLATION .............. 13 . ENGINE COOLANT CAPACITY (APPROXI-
COOLING FAN ........................................................ 14
. MATE) ................................................................. 25
.
Removal and Installation (Crankshaft driven type) 14 ... RESERVOIR CAP .............................................. 25 .
REMOVAL .......................................................... 14
. THERMOSTAT ................................................... 25 .
INSPECTION AFTER REMOVAL ...................... 14 .
INSTALLATION .................................................. 14.
INSPECTION AFTER INSTALLATION .............. 14 .
VQ
PRECAUTIONS ....................................................... 26
.
Precautions for Liquid Gasket ............................... 26
.
REMOVAL OF LIQUID GASKET SEALING ....... 26 .
LIQUID GASKET APPLICATION PROCEDURE 26 ...
Revision: November 2005 CO-1 2005 Frontier
PREPARATION ........................................................ 27
. INSPECTION AFTER INSTALLATION ...............38 .
Special Service Tools ............................................ 27
. Removal and Installation (Motor driven type) ........39 .
Commercial Service Tools ..................................... 28 . REMOVAL ...........................................................39
.
OVERHEATING CAUSE ANALYSIS ....................... 29 . INSTALLATION ...................................................39 .
Troubleshooting Chart ........................................... 29. WATER PUMP ..........................................................40.
COOLING SYSTEM ................................................. 31 . Removal and Installation ........................................40 .
Cooling Circuit ....................................................... 31
. REMOVAL ...........................................................40
.
System Chart ......................................................... 32
. INSPECTION AFTER REMOVAL .......................42 .
ENGINE COOLANT ................................................. 33 . INSTALLATION ...................................................42 .
System Check ....................................................... 33
. INSPECTION AFTER INSTALLATION ...............43 .
CHECKING COOLING SYSTEM HOSES .......... 33 . WATER INLET AND THERMOSTAT ASSEMBLY ...45
CHECKING RESERVOIR LEVEL ...................... 33 . Removal and Installation ........................................45 .
CHECKING COOLING SYSTEM FOR LEAKS ... 33 REMOVAL ...........................................................45
.
CHECKING RESERVOIR CAP .......................... 33 . INSPECTION AFTER REMOVAL .......................45 .
CHECKING RADIATOR ..................................... 34 . INSTALLATION ...................................................46 .
Refilling Engine Coolant ........................................ 34. INSPECTION AFTER INSTALLATION ...............46 .
RADIATOR ............................................................... 35
. WATER OUTLET AND WATER PIPING ..................47 .
Removal and Installation ....................................... 35 . Removal and Installation ........................................47 .
REMOVAL .......................................................... 35
. REMOVAL ...........................................................47
.
INSTALLATION ................................................... 37
. INSTALLATION ...................................................47 .
INSPECTION AFTER INSTALLATION ............... 37 . INSPECTION AFTER INSTALLATION ...............47 .
ENGINE COOLING FAN .......................................... 38 . SERVICE DATA AND SPECIFICATIONS (SDS) .....49 .
Removal and Installation (Crankshaft driven type)... 38 Standard and Limit .................................................49.
REMOVAL .......................................................... 38
. ENGINE COOLANT CAPACITY (APPROXI-
INSPECTION AFTER REMOVAL ....................... 38 . MATE) .................................................................49
.
INSTALLATION ................................................... 38
. RADIATOR ..........................................................49
.
THERMOSTAT ..................................................
Revision: November 2005 CO-2 2005 Frontier
PRECAUTIONS
[QR]
PRECAUTIONS PFP:00001
A
Precautions for Liquid Gasket EBS00NHD
REMOVAL OF LIQUID GASKET SEALING
G After removing nuts and bolts, separate the mating surface, using Tool and remove old liquid gasket seal- CO
ing.
Tool number : KV10111100 (J-37228)
CAUTION: C
Be careful not to damage the mating surfaces.
G Tap Tool to insert it, and then slide it by tapping on the side as
shown. D
G In areas where Tool is difficult to use, use plastic hammer to
lightly tap the parts, to remove it.
CAUTION: E
If for some unavoidable reason suitable tool such as screw-
driver is used, be careful not to damage the mating sur- WBIA0566E
faces.
F
LIQUID GASKET APPLICATION PROCEDURE
1. Remove old liquid gasket adhering to the liquid gasket applica-
tion surface and the mating surface, Using scraper. G
G Remove liquid gasket completely from the groove of the liquid
gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering H
moisture, grease and foreign materials.
I
PBIC0003E
J
3. Attach liquid gasket tube to Tool.
Tool number : WS39930000 ( -- )
Use Genuine RTV Silicone Sealant or equivalent. Refer to K
GI-47, "Recommended Chemical Products and Sealants" .
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions. L
G If there is a groove for the liquid gasket application, apply liq-
uid gasket to the groove.
M
WBIA0567E
G As for the bolt holes, normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Make sure to read the text of service manual.
G Within five minutes of liquid gasket application, install the mat-
ing component.
G If liquid gasket protrudes, wipe it off immediately.
G Do not retighten nuts or bolts after the installation.
G After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION: SEM159F
If there are specific instructions in this manual, observe them.
Revision: November 2005 CO-3 2005 Frontier
PREPARATION
[QR]
PREPARATION PFP:00002
Special Service Tools EBS00NHE
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
EG17650301 Adapting radiator cap tester to radiator cap
(J-33984-A) and radiator filler neck
Radiator cap tester adapter a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
S-NT564
KV10111100 Removing chain tensioner cover and water
(J-37228) pump cover
Seal cutter
NT046
WS39930000 Pressing the tube of liquid gasket
( -- )
Tube presser
S-NT052
-- Checking concentration of ethylene glycol in
(J-23688) engine coolant
Engine coolant refractometer
WBIA0539E
Commercial Service Tools EBS00NGN
Tool name Description
Power tool Loosening nuts and bolts
PBIC0190E
Radiator cap tester Checking radiator and radiator cap
PBIC1982E
Revision: November 2005 CO-4 2005 Frontier
OVERHEATING CAUSE ANALYSIS
[QR]
OVERHEATING CAUSE ANALYSIS PFP:00012
A
Troubleshooting Chart EBS00NGO
Symptom Check items
Water pump malfunction Worn or loose drive belt CO
Thermostat and water con-
--
trol valve stuck closed
C
Dust contamination or
Poor heat transfer --
Damaged fins paper clogging
Physical damage
D
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
ate E
Reduced air flow High resistance to fan rota- Fan assembly --
tion
F
Damaged fan blades
Damaged radiator shroud -- -- --
Cooling sys- Improper engine coolant G
-- -- --
tem parts mixture ratio
malfunction Poor engine coolant quality -- Engine coolant viscosity --
Loose clamp H
Cooling hose
Cracked hose
Water pump Poor sealing
I
Loose
Radiator cap
Poor sealing
Engine coolant leaks
O-ring for damage, deterio- J
Insufficient engine coolant ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core K
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leaks into L
Overflowing reservoir tank Cylinder head gasket dete-
cooling system
rioration
M
Revision: November 2005 CO-5 2005 Frontier
OVERHEATING CAUSE ANALYSIS
[QR]
Symptom Check items
High engine rpm under no
load
Driving in low gear for
Abusive driving
extended 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
Blocked or restricted air paper clogging --
flow
Blocked radiator --
Blocked condenser
Blocked air flow
Installed large fog lamp
Revision: November 2005 CO-6 2005 Frontier
COOLING SYSTEM
[QR]
COOLING SYSTEM PFP:21020
A
Cooling Circuit EBS00NGP
CO
C
D
E
F
G
H
I
J
K
L
PBIC3008E
M
Revision: November 2005 CO-7 2005 Frontier
COOLING SYSTEM
[QR]
System Chart EBS00NGQ
PBIC3009E
Revision: November 2005 CO-8 2005 Frontier
ENGINE COOLANT
[QR]
ENGINE COOLANT PFP:KQ100
A
System Check EBS00NHF
WARNING:
G Never remove the radiator cap or reservoir tank cap when the engine is hot. Serious burns could CO
occur from high pressure fluid escaping from the radiator.
G Wrap a thick cloth around the cap. Slowly push down and turn it a quarter turn to allow built-up
pressure to escape. Carefully remove the cap by pushing down and turning it all the way. C
CHECKING COOLING SYSTEM HOSES
Check hoses for the following:
G Improper attachment D
G Leaks
G Cracks
E
G Damage
G Loose connections
G Chafing F
G Deterioration
CHECKING RESERVOIR LEVEL
G Check if the reservoir tank coolant level is within MIN to MAX G
when the engine is cool.
G Adjust engine coolant level as necessary.
H
I
J
SMA412B
CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system using K
Tool.
Tool number : EG17650301 (J-33984-A)
L
Testing pressure : 137 kPa (1.4 kg/cm2 , 20 psi)
WARNING:
Never remove the radiator cap when the engine is hot. Serious M
burns could occur from high pressure coolant escaping from
the radiator.
CAUTION: WBIA0568E
Higher pressure than specified may cause radiator damage.
CHECKING RESERVOIR CAP
1. Inspect the reservoir cap.
G Replace the cap if the metal plunger cannot be seen around the edge of the black rubber gasket.
G Replace the cap if deposits of waxy residue or other foreign material are on the black rubber gasket or
the metal retainer.
NOTE:
Thoroughly wipe out the reservoir filler neck to remove any waxy residue or foreign material.
Revision: November 2005 CO-9 2005 Frontier
ENGINE COOLANT
[QR]
2. Pull the negative-pressure valve to open it and check that it
closes completely when released.
G Check that there is no dirt or damage on the valve seat of the
reservoir cap negative-pressure valve.
G Check that there are no abnormalities in the opening and
closing conditions of the negative-pressure valve.
SMA967B
3. Check reservoir cap relief pressure using Tool.
Tool number : EG17650301 (J-33984-A)
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