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ENGINE COOLING SYSTEM

B ENGINE

ENGINE COOLING SYSTEM
SECTION CO CO

E
CONTENTS
CR WATER PUMP ......................................................... 23
. F
Removal and Installation ....................................... 23
.
PRECAUTIONS ......................................................... 3 . REMOVAL .......................................................... 23
.
Precautions For Liquid Gasket ................................ 3 . INSPECTION AFTER REMOVAL ...................... 24 . G
REMOVAL OF LIQUID GASKET SEALING ......... 3 . INSTALLATION .................................................. 24
.
LIQUID GASKET APPLICATION PROCEDURE 3 ..... INSPECTION AFTER INSTALLATION ............... 24 .
PREPARATION .......................................................... 4 . THERMOSTAT ......................................................... 25
.
Special Service Tools .............................................. 4 . H
Removal and Installation ....................................... 25
.
Commercial Service Tool ........................................ 5 . REMOVAL .......................................................... 25
.
OVERHEATING CAUSE ANALYSIS ......................... 6 . INSPECTION AFTER REMOVAL ...................... 25 .
Troubleshooting Chart ............................................. 6 . INSTALLATION .................................................. 26
. I
COOLING SYSTEM ................................................... 8 . INSPECTION AFTER INSTALLATION ............... 26 .
Cooling Circuit ......................................................... 8
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 27 .
ENGINE COOLANT ................................................... 9 . Standard and Limit ................................................. 27
. J
Inspection ................................................................ 9
. CAPACITY .......................................................... 27
.
LEVEL CHECK .................................................... 9 . THERMOSTAT ................................................... 27
.
LEAK CHECK ...................................................... 9 . RADIATOR ......................................................... 27
.
Changing Engine coolant ...................................... 10 . K
Tightening Torque .................................................. 27
.
DRAINING ENGINE COOLANT ........................ 10 .
REFILLING ENGINE COOLANT ........................11 .
FLUSHING COOLING SYSTEM ........................ 12 .
HR L
RADIATOR ............................................................... 13. PRECAUTIONS ....................................................... 28 .
Removal and Installation ....................................... 13 . Precautions For Liquid Gasket .............................. 28 .
REMOVAL .......................................................... 14 . REMOVAL OF LIQUID GASKET SEALING ....... 28 . M
INSTALLATION .................................................. 16 . LIQUID GASKET APPLICATION PROCEDURE 28 ...
Disassembly and Assembly of Cooling Fan .......... 16 . PREPARATION ........................................................ 29.
DISASSEMBLY .................................................. 17 . Special Service Tools ............................................ 29 .
ASSEMBLY ........................................................ 17 . Commercial Service Tool ....................................... 30 .
Checking Radiator Cap (M/T Models without A/C OVERHEATING CAUSE ANALYSIS ....................... 31 .
and A/T Models) .................................................... 17 . Troubleshooting Chart ........................................... 31 .
Checking Reservoir Tank Cap (M/T Models with A/ COOLING SYSTEM ................................................. 33 .
C) .......................................................................... 18
. Cooling Circuit ....................................................... 33
.
Checking Cooling System Hoses .......................... 18 . ENGINE COOLANT ................................................. 34 .
RADIATOR (ALUMINUM TYPE) ............................. 19 . Inspection .............................................................. 34
.
Disassembly and Assembly .................................. 19 . LEVEL CHECK ................................................... 34 .
PREPARATION .................................................. 19 . LEAK CHECK ..................................................... 34 .
DISASSEMBLY .................................................. 19 . Changing Engine coolant ...................................... 35 .
ASSEMBLY ........................................................ 20 . DRAINING ENGINE COOLANT ......................... 35 .
INSPECTION ..................................................... 22 . REFILLING ENGINE COOLANT ........................ 36 .
FLUSHING COOLING SYSTEM ........................ 37 .

CO-1
RADIATOR ............................................................... 38
. K9K
Removal and Installation ....................................... 38 .
REMOVAL .......................................................... 39
. APPLICATION NOTICE ...........................................55 .
INSTALLATION ................................................... 41
. How to Check Vehicle Type ...................................55 .
Disassembly and Assembly of Cooling Fan .......... 41 . PRECAUTIONS ........................................................56 .
DISASSEMBLY .................................................. 42 . Precautions For Liquid Gasket ...............................56 .
ASSEMBLY ........................................................ 42
. REMOVAL OF LIQUID GASKET ........................56 .
Checking Radiator Cap (Without A/C Models) ...... 42 . LIQUID GASKET APPLICATION PROCEDURE...56
Checking Reservoir Tank Cap (With A/C Models)... 43 PREPARATION ........................................................57 .
Checking Radiator ................................................. 43
. Special Service Tools .............................................57 .
Checking Cooling System Hoses .......................... 43 . OVERHEATING CAUSE ANALYSIS .......................58 .
RADIATOR (ALUMINUM TYPE) .............................. 44 . Troubleshooting Chart ............................................58 .
Disassembly and Assembly ................................... 44 . COOLING SYSTEM .................................................60 .
PREPARATION .................................................. 44 . Cooling Circuit ........................................................60
.
DISASSEMBLY .................................................. 44 . ENGINE COOLANT .................................................61 .
ASSEMBLY ........................................................ 45
. Inspection ...............................................................61
.
INSPECTION ...................................................... 47
. LEVEL CHECK ...................................................61 .
WATER PUMP .......................................................... 48
. LEAK CHECK .....................................................61 .
Removal and Installation ....................................... 48 . Changing Engine Coolant ......................................62 .
REMOVAL .......................................................... 48
. DRAINING ENGINE COOLANT .........................62 .
INSPECTION AFTER REMOVAL ....................... 49 . REFILLING ENGINE COOLANT ........................62 .
INSTALLATION ................................................... 49
. FLUSHING COOLING SYSTEM ........................63 .
INSPECTION AFTER INSTALLATION ............... 49 . RADIATOR ...............................................................64
.
THERMOSTAT ......................................................... 50
. Removal and Installation ...................................... ..64 .
Removal and Installation ....................................... 50 . REMOVAL ...........................................................65.
REMOVAL .......................................................... 50
. INSTALLATION ...................................................66 .
INSPECTION AFTER REMOVAL ....................... 50 . Disassembly and Assembly Radiator Fan .............66 .
INSTALLATION ................................................... 51
. DISASSEMBLY ...................................................67 .
INSPECTION AFTER INSTALLATION ............... 51 . ASSEMBLY .........................................................68 .
WATER OUTLET ...................................................... 52
. Checking Reservoir Tank Cap ...............................68 .
Removal and Installation ....................................... 52 . Checking Radiator .................................................68 .
REMOVAL .......................................................... 52
. WATER PUMP ..........................................................69 .
INSTALLATION ................................................... 52
. Removal and Installation ...................................... ..69 .
INSPECTION AFTER INSTALLATION ............... 53 . REMOVAL ...........................................................69.
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 54 . INSPECTION AFTER REMOVAL .......................69 .
Standard and Limit ................................................. 54
. INSTALLATION ...................................................70 .
CAPACITY .......................................................... 54
. INSPECTION AFTER INSTALLATION ...............70 .
THERMOSTAT ................................................... 54 . THERMOSTAT ..........................................................71 .
RADIATOR ......................................................... 54
. Inspection ...............................................................71
.
WATER OUTLET ......................................................72 .
Removal and Installation ...................................... ..72 .
REMOVAL ...........................................................72.
INSTALLATION ...................................................72 .

CO-2
PRECAUTIONS
[CR]
PRECAUTIONS
[CR] PFP:00001
A
Precautions For Liquid Gasket EBS00OJI

REMOVAL OF LIQUID GASKET SEALING
q After removing the mounting bolts and nuts, separate the mating CO
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
C
q In areas where the seal cutter is difficult to use, use a plastic
hammer to lightly tap the gasket area.
CAUTION:
D
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
PBIC0275E
E
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface. F
q Remove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts and bolt holes.
2. Wipe the gasket application surface and the mating surface with G
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser. H
Use Genuine Liquid Gasket or equivalent.
PBIC0003E

I
4. Apply the gasket without breaks to the specified location with the
specified dimensions.
q If there is a groove for the liquid gasket application, apply the J
gasket to the groove.

L
EMA0622D

q As for the bolt holes, normally apply the gasket inside the holes. M
Occasionally, it should be applied outside the holes. Make sure
to read the instruction in this manual.
q Within five minutes of gasket application, install the mating com-
ponent.
q If the liquid gasket protrudes, wipe it off immediately.
q Do not retighten after the installation.
q After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION: SEM164F
If there are additional instructions in this manual, observe them.

CO-3
PREPARATION
[CR]
PREPARATION PFP:00002

Special Service Tools EBS00OJJ

NISSAN Tool number
(RENAULT tool number) Description
Tool name

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

S-NT052

EG17650301 Adapting radiator cap tester to 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

KV99103510 Installing radiator upper and lower tanks
( -- )
Radiator plate pliers A

S-NT224

KV99103520 Removing radiator upper and lower tanks
( -- )
Radiator plate pliers B

S-NT225

-- Leak checking
(M.S. 554_07) Checking reservoir tank and reservoir tank
Tester cap

MLIA0012E

-- Adapting tester to reservoir tank
(M.S. 554_01)
Reservoir tank tester adapter

MLIA0013E

-- Adapting tester to reservoir tank cap
(M.S. 554_06)
Reservoir tank cap tester adapter

MLIA0014E

CO-4
PREPARATION
[CR]
Commercial Service Tool EBS01JAW

A
Tool name Description

Radiator cap tester Checking radiator and radiator cap
CO

PBIC1982E

CO-5
OVERHEATING CAUSE ANALYSIS
[CR]
OVERHEATING CAUSE ANALYSIS PFP:00012

Troubleshooting Chart EBS00OIR

Symptom Check items
Water pump malfunction Worn or loose drive belt
Thermostat stuck closed --
Dust contamination or
Poor heat transfer Damaged fins paper clogging --
Mechanical damage
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
ate
Reduced air flow High resistance to fan rota- Fan assembly --
tion
Damaged fan blades
Damaged radiator shroud -- -- --
Improper coolant mixture
-- -- --
ratio
Cooling sys-
Poor coolant quality -- Coolant viscosity --
tem parts
malfunction Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Radiator cap (M/T models Loose
without A/C and A/T mod-
els
Reservoir tank cap (M/T Poor sealing
Engine coolant leaks
models with A/C)
Insufficient engine coolant O-ring for damage, deterio-
ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leaks into
Overflowing reservoir tank Cylinder head gasket dete-
cooling system
rioration

CO-6
OVERHEATING CAUSE ANALYSIS
[CR]
Symptom Check items
A
High engine rpm under no
load
Driving in low gear for
Abusive driving CO
extended time
Driving at extremely high
speed
-- Overload on engine C
Powertrain system mal-
function
Installed improper size
Except cool- --
wheels and tires D
ing system
parts mal- Dragging brakes
function
Improper ignition timing
E
Blocked bumper --
Installed car brassiere
Blocked radiator grille Mud contamination or F
Blocked or restricted air paper clogging --
flow
Blocked radiator --
Blocked condenser G
Blocked air flow
Installed large fog lamp

CO-7
COOLING SYSTEM
[CR]
COOLING SYSTEM PFP:21020

Cooling Circuit EBS00OIS

PBIC1475E

CO-8
ENGINE COOLANT
[CR]
ENGINE COOLANT PFP:KQ100
A
Inspection EBS00OJK

LEVEL CHECK
M/T Models without A/C and A/T Models CO
q Check if the reservoir tank engine coolant level is within "MIN" to
"MAX" when engine is cool.
q adjust the engine coolant level as necessary. C

E
SMA412B

M/T Models with A/C
q Check if the reservoir tank coolant level is within MIN to MAX when engine is cool. F
q Adjust coolant if too much or too little.
Vehicle front
G

MBIB1360E
J

M
MBIA0092E

LEAK CHECK
M/T Model without A/C and A/T Models
q To check for leakage, apply pressure to the cooling system with
a radiator cap tester (commercial service tool) and radiator cap
tester adapter (SST).
Testing pressure : 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
Never remove the radiator cap when the engine is hot. Seri-
ous burns could occur from high pressure coolant escap-
ing from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage. SLC134B

CO-9
ENGINE COOLANT
[CR]
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
q If anything is found, repair or replace damaged parts.
M/T Models with A/C
q To check for leakage, fit the adapter to the reservoir tank (1),
and then connect it to the tester.

MBIB1362E

q Warm up the engine and turn it off.
q Apply pressure to the cooling system and stop pumping.
Testing pressure : 10 kpa
(0.1 bar, 0.10 kg/cm2 , 1.5 psi)
q If the pressure drops, look for leakage.
q Unscrew slowly the adapter from the reservoir tank to reduce
the pressure in cooling system, and install the reservoir tank
cap.
WARNING:
Never remove the reservoir tank cap when the engine is MBIA0094E
hot. Serious burns could occur from high pressure engine
coolant escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
Changing Engine coolant EBS00OIV

WARNING:
q To avoid being scalded, never change the coolant when the engine is hot.
q Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter
of a turn to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT
M/T Models without A/C and A/T Models
1. Disconnect radiator lower hose and radiator cap.
CAUTION:
Make sure to drain when the engine coolant temperature is cold.

2. Remove reservoir tank and drain the engine coolant in the fol-
lowing procedures.
a. Move relay case in front of the battery.
b. Disconnect the reservoir tank from fan shroud to remove. With
force applied in the left direction of vehicle, pull up reservoir
tank.
3. Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
Refer to CO-12, "FLUSHING COOLING SYSTEM" .
PBIC1476E

CO-10
ENGINE COOLANT
[CR]
M/T Models with A/C
1. Disconnect radiator lower hose and reservoir tank cap. A
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
CO
2. Remove reservoir tank and drain the engine coolant.
: Vehicle front
C
3. Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
D
Refer to CO-12, "FLUSHING COOLING SYSTEM" .

E
MBIB1360E

REFILLING ENGINE COOLANT
1. Install reservoir tank. F
2. Connect radiator lower hose.
3. Disconnect heater hose (at heater hose outlet side: upper side)
as shown in figure. Keep hose end at the same height as that of G
before removal.

PBIC1477E
J
4. Fill radiator and reservoir tank to specified level.
q Pour coolant slowly of less than 2 (1-3/4 lmp qt) a
minute to allow air in system to escape. K
q When coolant from heater hose starts to drain, connect
heater hose and continue to fill.
q Use Genuine Nissan Anti-freeze Coolant or equivalent
L
mixed with water (distilled or demineralized).
Refer to MA-35, "RECOMMENDED FLUIDS AND LUBRI-
CANTS". M
SMA182B

Engine coolant capacity
M/T models with A/C and A/T models
With reservoir tank : Approx. 4.9 (4-3/8 Imp qt)
Reservoir tank : 0.7 (5/8 lmp qt)

SMA412B

CO-11
ENGINE COOLANT
[CR]
M/T models with A/C
With reservoir tank : Approx. 5.3 (4-5/8 Imp qt)
Reservoir tank : 1.2 (1-1/8 lmp qt)

: Vehicle front

MBIB1360E

MBIA0092E

5. Warm up engine to normal operating temperature with radiator cap installed.
6. Warm up until thermostat opens. Keep warming at 3,000 rpm for approximately 10 minutes as guide.
q For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot.

CAUTION:
Be careful not to overheat.
7. Stop the engine.
8. After cooling engine [approximately 50

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