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CO


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B ENGINE

                                                                                                                                                               A


                                                                                                                                                               CO
                                                                                              SECTION
                                                                        ENGINE COOLING SYSTEM                                                                  C


                                                                                                                                                               D


                                                                                                                                                               E
                                                               CONTENTS
PRECAUTIONS ......................................................... 2
                                                                     .            INSTALLATION .................................................. 14  .        F
 Precautions for Liquid Gasket ................................. 2   .            INSPECTION AFTER INSTALLATION ............... 15                    .
   REMOVAL OF LIQUID GASKET SEALING ......... 2                      .          Removal and Installation (Motor driven type) ........ 15              .
   LIQUID GASKET APPLICATION PROCEDURE 2                             .....        REMOVAL .......................................................... 15
                                                                                                                                                      .        G
PREPARATION .......................................................... 3
                                                                     .            INSTALLATION .................................................. 15  .
 Special Service Tools .............................................. 3
                                                                     .         WATER PUMP ......................................................... 16.
 Commercial Service Tools ....................................... 4  .          Removal and Installation ....................................... 16   .
                                                                                                                                                               H
OVERHEATING CAUSE ANALYSIS ......................... 5               .            REMOVAL .......................................................... 16
                                                                                                                                                      .
 Troubleshooting Chart ............................................. 5
                                                                     .            INSPECTION AFTER REMOVAL ...................... 18                  .
COOLING SYSTEM ................................................... 7 .            INSTALLATION .................................................. 18  .
 Cooling Circuit ......................................................... 7
                                                                     .            INSPECTION AFTER INSTALLATION ............... 19                    .         I
 System Chart .......................................................... 8
                                                                     .         WATER INLET AND THERMOSTAT ASSEMBLY ... 21
ENGINE COOLANT ................................................... 9 .          Removal and Installation ....................................... 21   .
 System Check ......................................................... 9
                                                                     .            REMOVAL .......................................................... 21
                                                                                                                                                      .        J
   CHECKING COOLING SYSTEM HOSES ........... 9                       .            INSPECTION AFTER REMOVAL ...................... 21                  .
   CHECKING RESERVOIR LEVEL ........................ 9               .            INSTALLATION .................................................. 22  .
   CHECKING COOLING SYSTEM FOR LEAKS..... 9                                       INSPECTION AFTER INSTALLATION ............... 22                    .
                                                                                                                                                               K
   CHECKING RESERVOIR CAP .......................... 10              .         WATER OUTLET AND WATER PIPING .................. 23                    .
   CHECKING RADIATOR ..................................... 10        .          Removal and Installation ....................................... 23   .
 Refilling Engine Coolant ........................................ 10.            REMOVAL .......................................................... 23
                                                                                                                                                      .
RADIATOR ................................................................11
                                                                     .            INSTALLATION .................................................. 23  .        L
 Removal and Installation ........................................11 .            INSPECTION AFTER INSTALLATION ............... 23                    .
   REMOVAL ...........................................................11
                                                                     .         SERVICE DATA AND SPECIFICATIONS (SDS) ..... 25                         .
   INSTALLATION .................................................. 13.          Standard and Limit ................................................. 25
                                                                                                                                                      .        M
   INSPECTION AFTER INSTALLATION .............. 13                   .            ENGINE COOLANT CAPACITY (APPROXI-
ENGINE COOLING FAN ......................................... 14      .            MATE) ................................................................. 25
                                                                                                                                                      .
 Removal and Installation (Crankshaft driven type) 14                ...          RADIATOR ......................................................... 25
                                                                                                                                                      .
   REMOVAL .......................................................... 14
                                                                     .            THERMOSTAT ................................................... 25   .
   INSPECTION AFTER REMOVAL ...................... 14                .




Revision: February 2006                                                  CO-1                                                               2005 Xterra
                                               PRECAUTIONS

PRECAUTIONS                                                                                          PFP:00001

Precautions for Liquid Gasket                                                                            EBS00NLV

REMOVAL OF LIQUID GASKET SEALING
G    After removing nuts and bolts, separate the mating surface, using Tool and remove old liquid gasket seal-
     ing.
         Tool number      : KV10111100 (J-37228)
     CAUTION:
     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.
G    In areas where Tool is difficult to use, use plastic hammer to
     lightly tap the parts, to remove it.
     CAUTION:
     If for some unavoidable reason suitable tool such as screw-
     driver is used, be careful not to damage the mating sur-                                         WBIA0566E

     faces.
LIQUID GASKET APPLICATION PROCEDURE
1.   Remove old liquid gasket adhering to the liquid gasket applica-
     tion surface and the mating surface, Using scraper.
     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
     moisture, grease and foreign materials.




                                                                                                      PBIC0003E



3.   Attach liquid gasket tube to Tool.
         Tool number      : WS39930000 (     --   )
     Use Genuine RTV Silicone Sealant or equivalent. Refer to
     GI-46, "Recommended Chemical Products and Sealants" .
4.   Apply liquid gasket without breaks to the specified location with
     the specified dimensions.
     G If there is a groove for the liquid gasket application, apply liq-
       uid gasket to the groove.


                                                                                                      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: February 2006                               CO-2                                        2005 Xterra
                                                       PREPARATION

PREPARATION                                                                                                                   PFP:00002
                                                                                                                                             A
Special Service Tools                                                                                                             EBS00NLW

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
  Tool number                                                                            Description
                                                                                                                                             CO
  (Kent-Moore No.)
  Tool name
  EG17650301                                                                             Adapting radiator cap tester to radiator cap
  (J-33984-A)                                                                            and radiator filler neck                            C
  Radiator cap tester adapter                                                            a: 28 (1.10) dia.
                                                                                         b: 31.4 (1.236) dia.
                                                                                         c: 41.3 (1.626) dia.
                                                                                         Unit: mm (in)                                       D

                                                                         S-NT564


  KV10111100                                                                             Removing chain tensioner cover and water            E
  (J-37228)                                                                              pump cover
  Seal cutter

                                                                                                                                             F


                                                                         NT046
                                                                                                                                             G
  WS39930000                                                                             Pressing the tube of liquid gasket
  ( -- )
  Tube presser
                                                                                                                                             H



                                                                         S-NT052
                                                                                                                                              I
      --                                                                                 Checking concentration of ethylene glycol in
  (J-23688)                                                                              engine coolant
  Engine coolant refractometer                                                                                                               J



                                                                                                                                             K
                                                                         WBIA0539E




                                                                                                                                             L



                                                                                                                                             M




Revision: February 2006                                         CO-3                                                       2005 Xterra
                           PREPARATION

Commercial Service Tools                                                           EBS00NLX


  Tool name                                   Description
  Power tool                                  Loosening nuts and bolts




                                  PBIC0190E


  Radiator cap tester                         Checking radiator and radiator cap




                                  PBIC1982E




Revision: February 2006       CO-4                                            2005 Xterra
                                      OVERHEATING CAUSE ANALYSIS

OVERHEATING CAUSE ANALYSIS                                                                                                      PFP:00012
                                                                                                                                               A
Troubleshooting Chart                                                                                                               EBS00NLY


                                        Symptom                                                       Check items
                                              Water pump malfunction         Worn or loose drive belt                                          CO
                                              Thermostat stuck closed                     --
                                                                             Dust contamination or
                                              Damaged fins                                                                                     C
                Poor heat transfer                                           paper clogging                                --
                                              Heater pump                    Physical damage
                                              Clogged radiator cooling       Excess foreign material                                           D
                                              tube                           (rust, dirt, sand, etc.)
                                              Cooling fan does not oper-
                                              ate
                                                                                                                                               E
                Reduced air flow              High resistance to fan rota-   Fan assembly                                  --
                                              tion
                                              Damaged fan blades
                                                                                                                                               F
                Damaged radiator shroud                    --                             --                               --
                Improper engine coolant
 Cooling sys-                                              --                             --                               --
                mixture ratio                                                                                                                  G
 tem parts
 malfunction    Poor engine coolant quality                --                Engine coolant viscosity                      --
                                                                                                            Loose clamp
                                                                             Cooling hose                                                      H
                                                                                                            Cracked hose
                                                                             Water pump                     Poor sealing
                                                                                                            Loose
                                                                             Radiator cap                                                       I
                                                                                                            Poor sealing
                                              Engine coolant leaks
                                                                                                            O-ring for damage, deterio-
                Insufficient engine coolant                                                                 ration or improper fitting         J
                                                                             Radiator
                                                                                                            Cracked radiator tank
                                                                                                            Cracked radiator core
                                                                             Reservoir tank                 Cracked reservoir tank             K
                                                                                                            Cylinder head deterioration
                                                                             Exhaust gas leaks into
                                              Overflowing reservoir tank                                    Cylinder head gasket dete-
                                                                             cooling system                                                    L
                                                                                                            rioration



                                                                                                                                               M




Revision: February 2006                                         CO-5                                                        2005 Xterra
                                      OVERHEATING CAUSE ANALYSIS

                                            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
                                                                           Powertrain 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: February 2006                                            CO-6                                                   2005 Xterra
                                   COOLING SYSTEM

COOLING SYSTEM                                                                      PFP:21020
                                                                                                    A
Cooling Circuit                                                                          EBS00NLZ




                                                                                                    CO



                                                                                                    C


                                                                                                    D


                                                                                                    E



                                                                                                    F


                                                                                                    G


                                                                                                    H



                                                                                                     I

                                                                                   WBIA0641E


   1.   Cylinder block (RH)   2.   Oil cooler           3.   Cylinder head (RH)                     J
   4.   Water pump            5.   Radiator             6.   Water inlet
   7.   Thermostat            8.   Cylinder head (LH)   9.   Heater pump
   10. Cylinder block (LH)                                                                          K


                                                                                                    L



                                                                                                    M




Revision: February 2006                         CO-7                              2005 Xterra
                          COOLING SYSTEM

System Chart                                      EBS00NM0




                                            WBIA0642E




Revision: February 2006        CO-8        2005 Xterra
                                         ENGINE COOLANT

ENGINE COOLANT                                                                         PFP:KQ100
                                                                                                      A
System Check                                                                               EBS00NM1


WARNING:
G Never remove the radiator/reservoir cap when the engine is hot. Serious burns could occur from CO
  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 coolant level if it is too much or too little.
                                                                                                      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/reservoir cap when the engine is hot.                                       M
Serious burns could occur from high pressure coolant escap-
ing from the radiator.
CAUTION:                                                                                 WBIA0568E

Higher pressure than specified may cause radiator damage.




Revision: February 2006                           CO-9                               2005 Xterra
                                            ENGINE COOLANT

CHECKING RESERVOIR CAP
1.   Check reservoir cap relief pressure using Tool.
         Tool number      : EG17650301 (J-33984-A)

         Standard: 78 



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