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B ENGINE

CO
SECTION
ENGINE COOLING SYSTEM C

E
CONTENTS
QR25DE WATER PUMP ......................................................... 17 . F
Removal and Installation ....................................... 17 .
PRECAUTIONS ......................................................... 3. REMOVAL .......................................................... 17.
Precautions for Supplemental Restraint System INSPECTION AFTER REMOVAL ...................... 18 . G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- INSTALLATION .................................................. 18 .
SIONER" ................................................................. 3
. INSPECTION AFTER INSTALLATION ............... 18 .
Precautions for Liquid Gasket ................................. 3 . THERMOSTAT AND THERMOSTAT HOUSING ..... 19 .
REMOVAL OF LIQUID GASKET ......................... 3 . H
Removal and Installation ....................................... 19 .
LIQUID GASKET APPLICATION PROCEDURE 3 ..... REMOVAL .......................................................... 19.
PREPARATION .......................................................... 5
. INSPECTION AFTER REMOVAL ...................... 20 .
Special Service Tools .............................................. 5
. INSTALLATION .................................................. 20 . I
Commercial Service Tools ....................................... 6 . WATER CONTROL VALVE ...................................... 21 .
OVERHEATING CAUSE ANALYSIS ......................... 7 . Removal and Installation ....................................... 21 .
Troubleshooting Chart ............................................. 7. REMOVAL .......................................................... 21. J
COOLING SYSTEM ................................................... 8 . INSPECTION AFTER REMOVAL ...................... 22 .
Cooling Circuit ......................................................... 8
. INSTALLATION .................................................. 22 .
ENGINE COOLANT ................................................... 9 . SERVICE DATA AND SPECIFICATIONS (SDS) ..... 23 .
System Check ......................................................... 9
. K
Capacity ................................................................. 23
.
CHECKING COOLING SYSTEM HOSES ........... 9 . Thermostat ............................................................ 23
.
CHECKING RESERVOIR LEVEL ........................ 9 . Water Control Valve ............................................... 23 .
CHECKING COOLING SYSTEM FOR LEAKS..... 9 Radiator ................................................................. 23
. L
CHECKING RADIATOR CAP ............................... 9 .
CHECKING RADIATOR ..................................... 10 .
Refilling Engine Coolant ........................................ 10 .
VQ35DE
M
RADIATOR ................................................................11
. PRECAUTIONS ....................................................... 24.
Removal and Installation ........................................11 . Precautions for Supplemental Restraint System
REMOVAL ...........................................................11
. (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
INSTALLATION ...................................................11 . SIONER" ................................................................ 24
.
Disassembly and Assembly .................................. 12 . Precautions for Liquid Gasket ............................... 24 .
PREPARATION ................................................. 12 . REMOVAL OF LIQUID GASKET SEALING ....... 24 .
DISASSEMBLY .................................................. 12 . LIQUID GASKET APPLICATION PROCEDURE 24 ...
ASSEMBLY ........................................................ 13
. PREPARATION ........................................................ 26
.
INSPECTION ..................................................... 15. Special Service Tools ............................................ 26.
COOLING FAN ..................................................... 16. Commercial Service Tools ..................................... 26 .
DISASSEMBLY .................................................. 16 . OVERHEATING CAUSE ANALYSIS ....................... 27 .
ASSEMBLY ........................................................ 16
. Troubleshooting Chart ........................................... 27 .
COOLING SYSTEM ................................................. 29 .
Cooling Circuit ....................................................... 29
.

Revision: May 2004 CO-1 2004 Altima
ENGINE COOLANT ................................................. 30 . WATER PUMP ..........................................................38 .
System Check ....................................................... 30
. Removal and Installation ........................................38 .
CHECKING COOLING SYSTEM HOSES .......... 30 . REMOVAL ...........................................................38.
CHECKING RESERVOIR LEVEL ...................... 30 . INSPECTION AFTER REMOVAL .......................40 .
CHECKING COOLING SYSTEM FOR LEAKS ... 30 INSTALLATION ...................................................40 .
CHECKING RADIATOR CAP ............................. 30 . THERMOSTAT AND THERMOSTAT HOUSING ......43 .
CHECKING RADIATOR ..................................... 31 . Removal and Installation ........................................43 .
RADIATOR ............................................................... 32
. REMOVAL ...........................................................43.
Removal and Installation ....................................... 32 . INSPECTION AFTER REMOVAL .......................43 .
REMOVAL .......................................................... 32
. INSTALLATION ...................................................44 .
INSTALLATION ................................................... 32
. WATER OUTLET AND WATER PIPING ..................45 .
Disassembly and Assembly ................................... 33 . Removal and Installation ........................................45 .
PREPARATION .................................................. 33 . REMOVAL ...........................................................45.
DISASSEMBLY .................................................. 33 . INSTALLATION ...................................................45 .
ASSEMBLY ........................................................ 34
. SERVICE DATA AND SPECIFICATIONS (SDS) .....46 .
INSPECTION ...................................................... 36
. Capacity .................................................................46
.
COOLING FAN ...................................................... 37
. Thermostat .............................................................46
.
DISASSEMBLY .................................................. 37 . Radiator .................................................................46
.
ASSEMBLY ........................................................ 37
.

Revision: May 2004 CO-2 2004 Altima
PRECAUTIONS
[QR25DE]
PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT
BELT PRE-TENSIONER" EBS00EZ7

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along CO
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 C
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 and SB section of this Service Man-
ual.
WARNING: D
q To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer. E
q Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section. F
q 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
harness connectors.
G
Precautions for Liquid Gasket EBS00DWG

REMOVAL OF LIQUID GASKET
q After removing the mounting bolts and nuts, separate the mating H
surface using a seal cutter and remove the sealant.
CAUTION:
Be careful not to damage the mating surfaces. I
q In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the sealant is applied.
CAUTION: J
If for some unavoidable reason a tool such as a flat-blade
screwdriver is used, be careful not to damage the mating
surfaces.
PBIC0002E K
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old sealant adhering to the mating
L
surfaces.
q Remove the sealant completely from the groove of mating sur-
face, mounting bolts, and bolt holes.
M
2. Thoroughly clean the sealant mating surface removing all of the
adhering moisture, grease and foreign material.
3. Attach the sealant tube to the tube presser.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-43, "RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
PBIC0003E

Revision: May 2004 CO-3 2004 Altima
PRECAUTIONS
[QR25DE]
4. Apply the sealant without breaks to the specified location with
the specified dimensions.
q If there is a groove for the sealant application, apply the sealant
to the groove.

EMA0622D

q As for the bolt holes, normally apply the sealant inside the holes.
If specified, it should be applied outside the holes. Make sure to
read the instructions in this manual.
q Within five minutes of sealant application, install the mating
component.
q If the sealant protrudes, wipe it off immediately.
q Do not retighten the nuts and bolts after installation.
q After 30 minutes or more have passed from the installation, fill
the engine with the proper oil and coolant. Refer to MA-13,
"RECOMMENDED FLUIDS AND LUBRICANTS" . SEM159F
CAUTION:
If there are instructions in this manual, observe them.

Revision: May 2004 CO-4 2004 Altima
PREPARATION
[QR25DE]
PREPARATION PFP:00002
A
Special Service Tools EBS00DWH

The actual shape of the Kent-Moore tools may differ from those tools illustrated here.
Tool number Description CO
(Kent-Moore No.)
Tool name
WS39930000 Pressing the tube of liquid gasket C
( --- )
Tube presser

S-NT052
E
EG17650301 Adapting radiator cap tester to radiator filler
(J-33984-A) neck:
Radiator cap tester adapter a: 28 (1.10) dia.
b: 31.4 (1.236) dia. F
c: 41.3 (1.626) dia.
Unit: mm (in)

S-NT564 G
KV99103510 Installing radiator upper and lower tanks
( -- )
Radiator plate pliers A H

I
S-NT224

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

K
S-NT225

-- Checking concentration of ethylene glycol in L
(J-23688) engine coolant
Engine coolant refractometer

WBIA0539E

Revision: May 2004 CO-5 2004 Altima
PREPARATION
[QR25DE]
Commercial Service Tools EBS00DWI

Tool name Description
Power tool Loosening bolts and nuts

PBIC0190E

Revision: May 2004 CO-6 2004 Altima
OVERHEATING CAUSE ANALYSIS
[QR25DE]
OVERHEATING CAUSE ANALYSIS PFP:00012
A
Troubleshooting Chart EBS00DWJ

Symptom Check items
Water pump malfunction Worn or loose drive belt CO
Thermostat stuck closed Coolant circulation
Dust contamination or rock
C
Poor heat transfer Damaged fins clogging --
Mechanical 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- Engine cooling fans --
tion
Damaged fan blades
F
Damaged radiator shroud -- -- --
Improper coolant mixture
Cooling sys- -- -- --
ratio G
tem parts
malfunction Poor coolant quality -- Periodic maintenance --
Loose clamp
Cooling hose H
Cracked hose
Water pump Poor sealing
Loose
Radiator cap I
Poor sealing
Coolant leaks
O-ring for damage, deterio-
Insufficient 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
High engine rpm under no
load
M
Driving in low gear for
Abusive driving
extended time
Driving at extremely high
speed
-- Overload on engine
Powertrain system mal-
function
Except cool-
ing system Installed improper size
wheels and tires --
parts mal-
function Dragging brakes
Improper ignition timing
Blocked radiator grille Installed car brassiere
Blocked bumper
Blocked or restricted air
Blocked radiator Mud contamination or --
flow
Blocked condenser paper clogging

Installed large fog lamp

Revision: May 2004 CO-7 2004 Altima
COOLING SYSTEM
[QR25DE]
COOLING SYSTEM PFP:21020

Cooling Circuit EBS00DWK

WBIA0143E

PBIC0280E

Revision: May 2004 CO-8 2004 Altima
ENGINE COOLANT
[QR25DE]
ENGINE COOLANT PFP:KQ100
A
System Check EBS00EZ8

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure CO
fluid escaping from the radiator.
Wrap a thick cloth around the cap. Slowly push down and turn it a quarter turn to allow built-up pres-
sure 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:
q Improper attachment D
q Leaks
q Cracks
q Damage E
q Loose connections
q Chafing
F
q Deterioration
CHECKING RESERVOIR LEVEL
q Check if the reservoir tank coolant level is within MIN to MAX G
when the engine is cool.
q Adjust coolant level if it is too much or too little.
H

SMA412B J

CHECKING COOLING SYSTEM FOR LEAKS
To check for leakage, apply pressure to the cooling system with a
K
tester.
Testing pressure : 157 kPa (1.6 kg/cm2 , 23 psi)
WARNING: L
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator. M
CAUTION:
Higher pressure than specified may cause radiator damage.
SLC756A

CHECKING RADIATOR CAP
1. Inspect the radiator cap.
q Replace the cap if the metal plunger cannot be seen around the edge of the black rubber gasket.

q 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 radiator filler neck to remove any waxy residue or foreign material.

Revision: May 2004 CO-9 2004 Altima
ENGINE COOLANT
[QR25DE]
2. Pull the negative pressure valve to open it and check that it
closes completely when released.
q Check that there is no dirt or damage on the valve seat of the
radiator cap negative-pressure valve.
q Check that there are no abnormalities in the opening and
closing conditions of the negative-pressure valve.

SMA967B

3. Check radiator cap, apply pressure to cap using Tool.
Radiator cap relief pressure
Standard : 78 - 98 kPa (0.8 - 1.0 kg/cm2 , 11 - 14 psi)
Limit : 59 kPa (0.6 kg/cm2 , 14 psi)
q When connecting the radiator cap to the Tool, apply water or
coolant to the cap seal surface.
q Replace the cap if the there is an abnormality in the negative-
pressure valve, or if the open-valve pressure is outside of the
standard values. SLC755A

CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows.
q Be careful not to bend or damage the radiator fins.
q When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
shroud and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing when clear water flows off of the radiator.
4. Blow air into the back side of radiator core vertically downward.
q Use compressed air lower than 490 kPa (5 kg/cm2 , 71 psi) and keep distance more than 300 mm (11.8
in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
6. Check for leakage.
Refilling Engine Coolant EBS00EZ9

Changing the engine coolant is part of the required maintenance of the engine. Refer to MA-16, "Changing
Engine Coolant" .

Revision: May 2004 CO-10 2004 Altima
RADIATOR
[QR25DE]
RADIATOR PFP:21400
A
Removal and Installation EBS00T4U

WBIA0282E

1. Radiator 2. Radiator upper clip 3. Mounting rubber J
4. A/T fluid cooler hose (if equipped) 5. Radiator hose (lower) 6. Radiator fan assembly
7. Reservoir tank 8. Radiator hose (upper) 9. Radiator cap
10. Radiator core connection 11. Radiator drain plug K
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter of a turn L
to release built-up pressure. Carefully remove radiator cap by turning it all the way.
REMOVAL
M
1. Drain the coolant from the radiator. Refer to MA-16, "Changing Engine Coolant".
CAUTION:
Perform when engine is cold.
2. Remove fresh air duct. Refer to EM-17, "Removal and Installation".
3. Disconnect radiator upper and lower hoses.
4. Remove the A/T fluid cooler hoses, if equipped.
q Plug hoses to avoid leakage of A/T fluid.

5. Disconnect the reservoir tank hose.

Revision: May 2004 CO-11 2004 Altima
RADIATOR
[QR25DE]
6. Remove the radiator upper clips by pulling the tabs outside to
release the lock, as shown.
CAUTION:
To prevent damage, do not pull lock tabs excessively.
7. Remove radiator cooling fan assembly to radiator bolts.
8. Remove the radiator assembly.
CAUTION:
Do not damage or scratch air conditioner condenser and
radiator core when removing.
PBIC1216E

INSTALLATION
Installation is in the reverse order of removal, paying attention to the following.
q Fill the radiator with coolant. Refer to MA-16, "Changing Engine Coolant".
Installation of Radiator Upper Clip
q Install radiator upper clip on radiator core connection with the
following procedure:
1. Install the rubber on mounting pin of radiator core.
2. Align the radiator upper clip with the radiator core connection,
then insert the radiator upper clip straight into the radiator core
connections until a click is heard.
3. After connecting the radiator upper clip, use the following
method to make sure it is fully connected.
q Visually confirm that the two radiator upper clips are con-
nected to the radiator core connections. PBIC1241E
q Move the radiator upper clip and the radiator forward and
backward to make sure they are securely connected.
Disassembly and Assembly EBS00T4V

SLC882AB

Revision: May 2004 CO-12 2004 Altima
RADIATOR
[QR25DE]
PREPARATION
1. Attach the spacer to the tip of the Tool. A
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in)
wide x 8.5 mm (0.335 in) long.
2. Make sure that when Tool is closed dimension H is approx. 7.6 CO
mm (0.299 in).
3. Adjust dimension H with the spacer, if necessary.
C

SLC655CB
D

DISASSEMBLY
1. Remove the tank using Tool.
E
Tool number : KV99103520 ( -- )

SLC903-A
H
q Grip the crimped edge and bend it upwards so that Tool slips off.
CAUTION:
Do not bend excessively.
I

K
SLC893
q In areas where the Tool cannot be used, use a suitable tool to
bend the edge up.
CAUTION: L
Be careful not to damage tank.
2. Remove sealing rubber.
M

SLC930

3. Make sure the edge stands straight up, using a suitable tool.
4. Remove oil cooler from tank (if equipped).

SLC931

Revision: May 2004 CO-13 2004 Altima
RADIATOR
[QR25DE]
ASSEMBLY
1. Install the oil cooler (if equipped).
NOTE:
Pay attention to direction of conical washer.

SLC894
2. Clean the contact portion of the tank.

SLC932
3. Install sealing rubber by pushing it in with your fingers.
CAUTION:
Be careful not to twist sealing rubber gasket.

SLC917A

4. Crimp tank in specified sequence using Tool.
Tool number : KV99103510 ( -- )

SLC904-A

SLC896

Revision: May 2004 CO-14 2004 Altima
RADIATOR
[QR25DE]
q In the locations where Tool cannot be used use a suitable
tool. A

SLC897

D
5. Make sure that the rim is completely crimped down.
Standard height "H" : 8.0

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