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ENGINE COOLING SYSTEM

B ENGINE

ENGINE COOLING SYSTEM
SECTION CO CO

E
CONTENTS
CR THERMOSTAT ......................................................... 19
. F
Removal and Installation ....................................... 19
.
PRECAUTIONS ......................................................... 3. REMOVAL .......................................................... 19
.
Precautions For Liquid Gasket ................................ 3 . INSPECTION AFTER REMOVAL ...................... 19 . G
REMOVAL OF LIQUID GASKET SEALING ......... 3 . INSTALLATION .................................................. 20
.
LIQUID GASKET APPLICATION PROCEDURE 3 ..... INSPECTION AFTER INSTALLATION ............... 20 .
PREPARATION .......................................................... 4
. SERVICE DATA AND SPECIFICATIONS (SDS) ..... 21 .
Special Service Tools .............................................. 4. H
Standard and Limit ................................................. 21
.
Commercial Service Tool ........................................ 4 . CAPACITY .......................................................... 21
.
OVERHEATING CAUSE ANALYSIS ......................... 5 . THERMOSTAT ................................................... 21
.
Troubleshooting Chart ............................................. 5 . RADIATOR ......................................................... 21
. I
COOLING SYSTEM ................................................... 7 . Tightening Torque .................................................. 21
.
Cooling Circuit ......................................................... 7
.
ENGINE COOLANT ................................................... 8 . J
Inspection ................................................................ 8
.
HR
LEVEL CHECK .................................................... 8 . PRECAUTIONS ....................................................... 22 .
LEAK CHECK ...................................................... 8 . Precautions For Liquid Gasket .............................. 22 .
Changing Engine coolant ........................................ 9 . K
REMOVAL OF LIQUID GASKET SEALING ....... 22 .
DRAINING ENGINE COOLANT .......................... 9 . LIQUID GASKET APPLICATION PROCEDURE 22 ...
REFILLING ENGINE COOLANT ....................... 10 . PREPARATION ........................................................ 23.
FLUSHING COOLING SYSTEM .........................11 . Special Service Tools ............................................ 23 . L
RADIATOR ............................................................... 12
. Commercial Service Tool ....................................... 23 .
Removal and Installation ....................................... 12 . OVERHEATING CAUSE ANALYSIS ....................... 24 .
REMOVAL .......................................................... 13
. Troubleshooting Chart ........................................... 24 . M
INSTALLATION .................................................. 14 . COOLING SYSTEM ................................................. 26 .
Disassembly and Assembly of Cooling Fan .......... 14 . Cooling Circuit ....................................................... 26
.
DISASSEMBLY .................................................. 15 . ENGINE COOLANT ................................................. 27 .
ASSEMBLY ........................................................ 15. Inspection .............................................................. 27
.
Checking Radiator Cap (Models without A/C) ....... 15 . LEVEL CHECK ................................................... 27 .
Checking Reservoir Tank Cap (Models with A/C)... 16 LEAK CHECK ..................................................... 27 .
Checking Cooling System Hoses .......................... 16 . Changing Engine coolant ...................................... 28 .
WATER PUMP ......................................................... 17. DRAINING ENGINE COOLANT ......................... 28 .
Removal and Installation ....................................... 17 . REFILLING ENGINE COOLANT ........................ 29 .
REMOVAL .......................................................... 17
. FLUSHING COOLING SYSTEM ........................ 30 .
INSPECTION AFTER REMOVAL ...................... 18 . RADIATOR ............................................................... 31
.
INSTALLATION .................................................. 18 . Removal and Installation ....................................... 31 .
INSPECTION AFTER INSTALLATION .............. 18 . REMOVAL .......................................................... 32
.
INSTALLATION .................................................. 33 .
Disassembly and Assembly of Cooling Fan .......... 33 .
DISASSEMBLY .................................................. 34 .

CO-1
ASSEMBLY ........................................................ 34 . PREPARATION ........................................................44 .
Checking Radiator Cap (All Models Except M/T with Special Service Tools .............................................44 .
A/C) ....................................................................... 34
. OVERHEATING CAUSE ANALYSIS .......................45 .
Checking Reservoir Tank Cap (M/T with A/C Mod- Troubleshooting Chart ............................................45 .
els) ......................................................................... 35
. COOLING SYSTEM .................................................47 .
Checking Radiator ................................................. 35 . Cooling Circuit ........................................................47
.
Checking Cooling System Hoses .......................... 35 . ENGINE COOLANT .................................................48 .
WATER PUMP .......................................................... 36 . Inspection ...............................................................48
.
Removal and Installation ....................................... 36 . LEVEL CHECK ...................................................48 .
REMOVAL .......................................................... 36 . LEAK CHECK .....................................................48 .
INSPECTION AFTER REMOVAL ....................... 37 . Changing Engine Coolant ......................................49 .
INSTALLATION ................................................... 37 . DRAINING ENGINE COOLANT .........................49 .
INSPECTION AFTER INSTALLATION ............... 37 . REFILLING ENGINE COOLANT ........................49 .
THERMOSTAT ......................................................... 38 . FLUSHING COOLING SYSTEM ........................50 .
Removal and Installation ....................................... 38 . RADIATOR ...............................................................51
.
REMOVAL .......................................................... 38 . Removal and Installation ...................................... ..51 .
INSPECTION AFTER REMOVAL ....................... 38 . REMOVAL ...........................................................51.
INSTALLATION ................................................... 39 . INSTALLATION ...................................................52 .
INSPECTION AFTER INSTALLATION ............... 39 . Disassembly and Assembly Radiator Fan .............52 .
WATER OUTLET ...................................................... 40 . DISASSEMBLY ...................................................53 .
Removal and Installation ....................................... 40 . ASSEMBLY .........................................................53 .
REMOVAL .......................................................... 40 . Checking Reservoir Tank Cap ...............................53 .
INSTALLATION ................................................... 40 . Checking Radiator .................................................53 .
INSPECTION AFTER INSTALLATION ............... 41 . WATER PUMP ..........................................................54 .
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 42 . Removal and Installation ...................................... ..54 .
Standard and Limit ................................................. 42 . REMOVAL ...........................................................54.
CAPACITY .......................................................... 42 . INSPECTION AFTER REMOVAL .......................54 .
THERMOSTAT ................................................... 42 . INSTALLATION ...................................................55 .
RADIATOR ......................................................... 42 . INSPECTION AFTER INSTALLATION ...............55 .
THERMOSTAT ..........................................................56 .
K9K Inspection ...............................................................56
.
WATER OUTLET ......................................................57 .
PRECAUTIONS ........................................................ 43
. Removal and Installation ...................................... ..57 .
Precautions For Liquid Gasket .............................. 43 . REMOVAL ...........................................................57.
REMOVAL OF LIQUID GASKET ........................ 43 . INSTALLATION ...................................................57 .
LIQUID GASKET APPLICATION PROCEDURE 43 ...

CO-2
PRECAUTIONS
[CR]
PRECAUTIONS
[CR] PFP:00001
A
Precautions For Liquid Gasket BBS002RV

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 BBS002RW

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

-- 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

Commercial Service Tool BBS002RX

Tool name Description

Radiator cap tester Checking radiator and radiator cap

PBIC1982E

CO-4
OVERHEATING CAUSE ANALYSIS
[CR]
OVERHEATING CAUSE ANALYSIS PFP:00012
A
Troubleshooting Chart BBS002RY

Symptom Check items
Water pump malfunction Worn or loose drive belt CO
Thermostat stuck closed --
Dust contamination or
C
Poor heat transfer Damaged fins paper 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- Fan assembly --
tion
Damaged fan blades
F
Damaged radiator shroud -- -- --
Improper coolant mixture
-- -- --
ratio G
Cooling sys-
Poor coolant quality -- Coolant viscosity --
tem parts
malfunction Loose clamp
Cooling hose H
Cracked hose
Water pump Poor sealing
Radiator cap (M/T models Loose
I
without A/C and A/T mod-
els
Reservoir tank cap (M/T Poor sealing
Engine coolant leaks
models with A/C) J
Insufficient engine coolant O-ring for damage, deterio-
ration or improper fitting
Radiator
Cracked radiator tank K
Cracked radiator core
Reservoir tank Cracked reservoir tank
L
Cylinder head deterioration
Exhaust gas leaks into
Overflowing reservoir tank Cylinder head gasket dete-
cooling system
rioration
M

CO-5
OVERHEATING CAUSE ANALYSIS
[CR]
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

CO-6
COOLING SYSTEM
[CR]
COOLING SYSTEM PFP:21020
A
Cooling Circuit BBS002RZ

PBIC1475E

CO-7
ENGINE COOLANT
[CR]
ENGINE COOLANT PFP:KQ100

Inspection BBS002S0

LEVEL CHECK
Models without A/C
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.

SMA412B

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

MBIB1360E

MBIA0092E

LEAK CHECK
Model without A/C
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-8
ENGINE COOLANT
[CR]
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant. A
q If anything is found, repair or replace damaged parts.
Models with A/C
CO
q To check for leakage, fit the adapter to the reservoir tank (1),
and then connect it to the tester.

E
MBIB1362E

q Warm up the engine and turn it off.
q Apply pressure to the cooling system and stop pumping. F

Testing pressure : 90 kpa
(0.9 bar, 0.92 kg/cm2 , 13.1 psi) G
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 H
cap.
WARNING:
Never remove the reservoir tank cap when the engine is I
MBIA0094E
hot. Serious burns could occur from high pressure engine
coolant escaping from the radiator.
CAUTION: J
Higher pressure than specified may cause radiator damage.
Changing Engine coolant BBS002S1
K
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
L
of a turn to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT
Models without A/C M
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-11, "FLUSHING COOLING SYSTEM" .
PBIC1476E

CO-9
ENGINE COOLANT
[CR]
Models with A/C
1. Disconnect radiator lower hose and reservoir tank cap.
CAUTION:
Make sure to drain when the engine coolant temperature is cold.

2. Remove reservoir tank and drain the engine coolant.
: Vehicle front

3. Check drain coolant for contaminants such as rust, corrosion or
discoloration.
If contaminated, flush engine cooling system.
Refer to CO-11, "FLUSHING COOLING SYSTEM" .

MBIB1360E

REFILLING ENGINE COOLANT
1. Install reservoir tank.
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
before removal.

PBIC1477E

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.
q When coolant from heater hose starts to drain, connect
heater hose and continue to fill.
q Use Nissan Genuine Coolant L250 or equivalent mixed
with water (distilled or demineralized).
Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
SMA182B

Engine coolant capacity
Models without A/C
With reservoir tank : Approx. 4.9 (4-3/8 Imp qt)
Reservoir tank : 0.7 (5/8 lmp qt)

SMA412B

CO-10
ENGINE COOLANT
[CR]
Models with A/C
A
With reservoir tank : Approx. 5.3 (4-5/8 Imp qt)
Reservoir tank : 1.2 (1-1/8 lmp qt)
CO
: Vehicle front

MBIB1360E
E

MBIA0092E

5. Warm up engine to normal operating temperature with radiator cap installed. I
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: J
Be careful not to overheat.
7. Stop the engine.
8. After cooling engine [approximately 50

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