Engine Cooling System: Section

ENGINE
CO
A
CO
SECTION
ENGINE COOLING SYSTEM C
E
CONTENTS
KA24DE SERVICE DATA AND SPECIFICATIONS F
(SDS) ................................................................. 22
SERVICE INFORMATION ............................ 3 Standard and Limit ..................................................22
PRECAUTIONS ................................................... 3 YD25DDTi G
Precaution for Supplemental Restraint System SERVICE INFORMATION ........................... 23
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 3 PRECAUTIONS ................................................. 23 H
Precaution for Liquid Gasket ..................................... 3 Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
PREPARATION ................................................... 5 SIONER" .................................................................23 I
Special Service Tool ................................................. 5
Precaution for Liquid Gasket ...................................23
Commercial Service Tool .......................................... 5
PREPARATION ................................................. 25
OVERHEATING CAUSE ANALYSIS .................. 6 J
Special Service Tool ................................................25
Troubleshooting Chart ............................................... 6
Commercial Service Tool ........................................25
COOLING SYSTEM ............................................ 8 OVERHEATING CAUSE ANALYSIS ................ 26 K
Cooling Circuit ........................................................... 8
Troubleshooting Chart .............................................26
ENGINE COOLANT ............................................ 9 COOLING SYSTEM .......................................... 28
System Inspection ..................................................... 9 L
Cooling Circuit .........................................................28
Changing Engine Coolant ....................................... 10
ENGINE COOLANT .......................................... 32
RADIATOR .........................................................12 System Inspection ...................................................32 M
Component .............................................................. 12
Changing Engine Coolant ........................................33
Removal and Installation ......................................... 12
RADIATOR ........................................................ 35
COOLING FAN ...................................................15 Component ..............................................................35 N
Removal and Installation (Crankshaft Driven
Removal and Installation .........................................35
Type) ....................................................................... 15
Removal and Installation (Motor Driven Type) COOLING FAN .................................................. 38 O
(Models with A/C) .................................................... 16 Component (Crankshaft Driven Type) .....................38
Removal and Installation .........................................38
WATER PUMP ...................................................17 Removal and Installation (Motor Driven Type)
Removal .................................................................. 17 P
(Models with A/C) ....................................................39
Inspection ................................................................ 18
Installation ............................................................... 18 WATER PUMP .................................................. 40
Component ..............................................................40
THERMOSTAT ...................................................20 Removal and Installation .........................................40
Removal .................................................................. 20
Inspection ................................................................ 20 THERMOSTAT AND WATER PIPING .............. 42
Installation ............................................................... 20
Revision: March 2008 CO-1 2009 D22 LCV

Component ............................................................. 42 SERVICE DATA AND SPECIFICATIONS
Removal and Installation ........................................ 44 (SDS) ................................................................. 47
Standard and Limit .................................................. 47

PRECAUTIONS
< SERVICE INFORMATION > [KA24DE]
SERVICE INFORMATION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT CO
PRE-TENSIONER" INFOID:0000000003891693
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING: D
• 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 performed by
an authorized NISSAN/INFINITI dealer. E
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
F
• 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 har-
ness connectors.
G
Precaution for Liquid Gasket INFOID:0000000003897587
REMOVAL OF LIQUID GASKET SEALING H

• After removing nuts and bolts, separate the mating surface, using Tool and remove old liquid gasket sealing.
Tool number : KV10111100 (J-37228)

I
CAUTION:
Be careful not to damage the mating surfaces.
• Tap (1) Tool to insert it, and then slide it (2) by tapping on the side
J
as shown.
• In areas where Tool is difficult to use, use plastic hammer to lightly
tap the parts, to remove it.
CAUTION: K
If for some unavoidable reason suitable tool such as screw-
driver is used, be careful not to damage the mating surfaces. WBIA0566E
LIQUID GASKET APPLICATION PROCEDURE L

1. Remove old liquid gasket adhering to the liquid gasket applica-
tion surface and the mating surface, Using scraper.
• Remove liquid gasket completely from the groove of the liquid M
gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials. N
O
PBIC0003E

PRECAUTIONS
3. Attach liquid gasket tube to Tool.
Tool number : WS39930000 ( — )

Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-43, "Recommended Chemical Product and Sealant".
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions.
WBIA0567E
• If there is a groove for the liquid gasket application, apply liq-

uid gasket to the groove.
• 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.
• Within five minutes of liquid gasket application, install the mat-
ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Do not retighten nuts or bolts after the installation.
• After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
SEM159F
CAUTION:
If there are specific instructions in this manual, observe them.

PREPARATION
PREPARATION
A
Special Service Tool INFOID:0000000003489894
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. CO
Tool number Description
(Kent-Moore No.)
Tool name
C
WS39930000 Pressing the tube of liquid gasket.
( — )
Tube presser
D
E
NT052
EG17650301 Adapting radiator cap tester to radiator filler

(J33984-A) neck.
Radiator cap tester adapter a: 28 (1.10) dia. F
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
G
NT564
KV10111100 Removing water pump and water inlet hous- H

(J-37228) ing.
Seal cutter
NT046
J
Commercial Service Tool INFOID:0000000003898793
K
Tool name Description
Power tool Loosening bolts and nuts.
L
PBIC0190E
Radiator cap tester Checking radiator and reservoir tank cap. N
PBIC1982E
P

OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart INFOID:0000000003489895
Symptom Check items

Water pump malfunction Worn or loose drive belt
Thermostat stuck closed Coolant circulation
Dust contamination or rock
Poor heat transfer Damaged fins clogging —
Mechanical damage
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Fan coupling does not oper-
ate
Reduced air flow High resistance to fan rota- Fan and coupling —
tion
Damaged fan blades
Damaged radiator shroud — Radiator shroud —
Improper coolant mixture
Cooling sys- — Coolant mixture ratio —
ratio
tem parts
malfunction Poor coolant quality — Periodic maintenance —
Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Loose
Radiator cap
Poor sealing
Coolant leaks
O-ring for damage, deterio-
Insufficient coolant ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leaks into cool-
Overflowing reservoir tank Cylinder head gasket deteri-
ing system
oration

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

G

COOLING SYSTEM
COOLING SYSTEM
Cooling Circuit INFOID:0000000003489896
ALC117

ENGINE COOLANT
ENGINE COOLANT
A
System Inspection INFOID:0000000003489897
WARNING: CO
• Never remove the radiator cap when the engine is hot. Serious burns could occur from high pres-
sure coolant escaping from the radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter turn to allow built-up pressure to
C
escape. Carefully remove the radiator cap by turning it all the way.
LEVEL CHECK
• Check if the reservoir tank engine coolant level is within MIN to D
MAX when engine is cool.
• Refill engine coolant if necessary. Refer to CO-10, "Changing
Engine Coolant".
E
SMA412B G
CHECKING COOLING SYSTEM HOSES
• Check hoses for improper attachment, leaks, cracks, damage, chafing and deterioration.
H
CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows:
CAUTION:
• Be careful not to bend or damage the radiator fins. I
• When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radia-
tor shroud and horns.
• Tape the harness connectors to prevent water from entering. J
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 water flows clear coming out of the radiator. K
4. Blow air into the back side of radiator core vertically downward.
• Use compressed air lower than 490 kPa (5 kg/cm2, 71 psi) and keep the air hose end more than 30 cm
(11.8 in) away from the core. L
5. Blow air again into all the radiator core surfaces once per minute until no water blows out and the core is
dry.
M
CHECKING COOLING SYSTEM FOR LEAKS
• To check for leakage, apply pressure to the cooling system with a
suitable tool and Tool.
CAUTION: N
Higher test pressure than specified may cause cooling sys-
tem damage.
O
Testing pressure : 157 kPa (1.6 kg/cm2, 23 psi)
Tool number : EG17650301 (J-33984-A) P

• If anything is found, repair or replace damaged parts. SLC756A
CHECKING RADIATOR CAP

ENGINE COOLANT
• To check radiator cap, apply pressure to radiator cap with a suit-
able tool and 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, 9 psi)
Tool number : EG17650301 (J-33984-A)

SLC755A
• Pull the negative pressure valve to open it.

Check that it closes completely when released.
SMA967B
Changing Engine Coolant INFOID:0000000003901233
WARNING:
• To avoid being scalded, do not change engine coolant when engine is hot.
• Wrap a thick cloth around cap and carefully remove cap. First, turn cap a quarter of a turn to release
built-up pressure. Then turn cap all the way.
• Be careful not to allow engine coolant to contact drive belts.
DRAINING ENGINE COOLANT
1. Open radiator drain plug at the bottom of radiator, and remove radiator cap.
CAUTION:
Be careful not to allow engine coolant to contact drive belts.
When draining all engine coolant in the system, also perform the following steps.
2. Open cylinder block drain plug. Refer to EM-53, "Component".
3. Remove reservoir tank, drain engine coolant, then clean reservoir tank.
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush engine cooling system.
REFILLING ENGINE COOLANT
1. Install reservoir tank.
• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-53,
"Component".
2. Install the radiator drain plug.
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring.
Radiator drain plug: : 1.2 N·m (0.12 kg-m, 11 in-lb)

3. Make sure that each hose clamp has been firmly tightened.

ENGINE COOLANT
4. Fill radiator and reservoir tank to the specified level.
• Pour engine coolant through engine coolant filler neck A
slowly of less than 2 (2-1/8 US qt, 1-3/4 lmp qt) a minute
to allow air in system to escape.
• Use Genuine Nissan Engine Coolant or equivalent mixed
CO
with water (distilled or demineralized). Refer to MA-12,
"Engine Coolant Mixture Ratio".
Engine coolant capacity : Approx. 7.7 (8-1/8 US qt, C

(with reservoir tank at 6-3/4 lmp qt)
“MAX” level) SMA182B
Reservoir tank capacity : 0.8 (7/8 US qt, 3/4 lmp qt)

(at “MAX” level) E
• When engine coolant overflows air relief hole, install air relief
plug and install the radiator cap.
F
G
SMA412B
5. Start engine and warm it up until it reaches normal operating temperature (10 minutes maximum). H
• If engine coolant overflows radiator filler hole, install radiator cap.
6. Keep racing at 2000-2500 rpm and refill through reservoir tank filler until engine coolant level stabilizes on
MAX. Close reservoir tank cap and continue warm up until thermostat is opened (check the radiator I
hose).
CAUTION:
Watch engine coolant temperature gauge so as not to overheat the engine.
J
7. Stop the engine. After it has completely cooled down (using a fan to reduce the time), start engine and
keep it at idling.
8. Check the engine coolant level and refill engine coolant only through reservoir tank filler.
K
9. If the engine coolant level lowered, repeat steps 4 through 7 checking that engine coolant level on reser-
voir tank is stabilized on MAX.
10. Check cooling system for leaks with engine running. L
11. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000
rpm with heater temperature controller set at several position between COOL and WARM.
• Sound may be noticeable at heater unit.
M
12. Repeat step 11 three times.
13. If sound is heard, bleed air from cooling system by repeating steps 4 through 7 until engine coolant level
no longer drops.
N
FLUSHING COOLING SYSTEM
1. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and
reservoir tank with water and reinstall radiator cap and reservoir tank cap. O
2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down. P
5. Drain water from the system. Refer to CO-10.
6. Repeat steps 1 through 5 until clear water begins to drain from radiator.

RADIATOR
RADIATOR
Component INFOID:0000000003489905
AWBIA0600GB
1. Radiator mounting bracket (upper) 2. Radiator filler cap 3. Radiator mounting rubber (upper)
4. Radiator seal (upper) 5. Radiator 6. Radiator seal (lower)
7. Radiator mounting rubber (lower) 8. Radiator drain plug O-ring 9. Radiator drain plug
10. Radiator hose clamps (lower) 11. Radiator hose clamps (upper) 12. Radiator hose clip (upper)
13. Radiator hose (upper) 14. Radiator hose clamps (lower) 15. Radiator hose (lower)
16. Radiator tube (lower) 17. Radiator hose (lower) 18. Radiator shroud (upper)
19. Radiator shroud (lower) 20. Reservoir tank 21. Reservoir tank hose clamps
22. Reservoir tank hose 23. Reservoir tank filler cap Front
Removal and Installation INFOID:0000000003489906
WARNING:
Do not remove radiator cap and/or reservoir tank cap when engine is hot. Serious burns could occur
from high-pressure engine coolant escaping from radiator and/or reservoir tank.
REMOVAL
1. Remove engine undercover.
2. Drain engine coolant from radiator. Refer to CO-10, "Changing Engine Coolant".
CAUTION:
• Perform this step when engine is cold.
• Do not spill engine coolant on drive belts.
3. Disconnect reservoir tank hose and remove reservoir tank.
4. Disconnect radiator hose (upper and lower).

RADIATOR
CAUTION:
Do not spill engine coolant on drive belts. A
5. Remove front air duct.
6. Remove radiator shroud (lower).
7. Remove radiator shroud (upper). CO
8. Remove radiator mounting brackets (upper).
9. Remove radiator.
CAUTION: C
Do not damage or scratch A/C condenser (if equipped) and radiator core when removing.
INSPECTION AFTER REMOVAL
D
Checking Reservoir Tank Cap
• Inspect valve seat of reservoir tank cap.
- Check if valve seat is swollen to the extent that the edge of the E
plunger cannot be seen when watching it vertically from the top.
- Check if valve seat has no soil and damage.
PBIC2816E
H
• Pull negative-pressure valve to open it, and make sure that it is
completely closed when released.
- Make sure that there is no dirt or damage on the valve seat of radi- I
ator cap negative-pressure valve.
- Make sure that there are no unusualness in the opening and clos-
ing conditions of negative-pressure valve.
J
K
SMA967B
• Check reservoir tank cap relief pressure. L
Standard : 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/

cm2, 11 - 14 psi) M
Limit : 59 kPa (0.59 bar, 0.6 kg/cm2, 9 psi)
- When connecting reservoir tank cap to the Tool and the radiator N
cap tester, apply engine coolant to the cap seal surface.
Tool number : EG17650301 (J-33984-A)

SLC755AC
O
• Replace reservoir tank cap if there is an unusualness in negative pressure valve, or if the relief pressure falls
below the limit. P
CAUTION:
When installing a radiator cap and reservoir tank cap, thoroughly wipe out the radiator and reservoir
tank filler neck to remove any waxy residue or foreign material.
Checking Radiator
Check radiator for mud or clogging. If necessary, clean radiator as follows.
NOTE:
• Be careful not to bend or damage the radiator fins.

RADIATOR
• 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 downwards.
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downwards.
NOTE:
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71 psi) and keep distance more than 30 cm
(11.8 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
INSTALLATION
Installation is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
• Check for leaks of engine coolant using the Tool and the radiator cap tester. Refer to CO-9, "System Inspec-
tion".
Tool number : EG17650301 (J-33984-A)

• Start and warm up engine. Visually check if there is no leaks of engine coolant.

COOLING FAN
COOLING FAN
A
Removal and Installation (Crankshaft Driven Type) INFOID:0000000003941936
REMOVAL CO
CAUTION:
• Do not release the drive belt tension by removing the fan/water pump pulley.
• Fan coupling cannot be disassembled and should be replaced as a unit. If front mark F is present, C
install fan so that side marked F faces the front.
1. Remove the front air duct.
2. Remove the power steering pump belt, generator belt and A/C compressor drive belt, if equipped. Refer to D
EM-16, "Removal and Installation".
3. Remove the cooling fan (6) and fan coupling (5).
• 1 - 4: Tightening sequence E
• (7): Water pump pulley
• (A): Front mark
• (B): Cooling fan bolts
• (C): Fan coupling nuts F
• : Front
AWBIA0602ZZ
INSPECTION AFTER REMOVAL H

WARNING:
When the engine is running, keep hands and clothing away from moving parts such as drive belts and
cooling fan. I
Fan Coupling
• Check fan coupling for rough operation, wobbling, oil leakage or
bent bimetal fins. J
SLC072
M
• After assembly, verify the cooling fan does not wobble or flap while
the engine is running.
N
SLC151B
INSTALLATION
CAUTION:
• Install the drive belt only after the fan and fan coupling to water pump flange bolts/nuts have been
properly tightened.

COOLING FAN
• Proper alignment of these components is essential. Improper alignment will cause them to wobble
and may eventually cause the fan to separate from the water pump, causing extensive damage.
1. Install the fan coupling (5) and tighten the fan coupling nuts (C)
to specification in the order as shown.
• (A): Front mark
• : Front
Fan coupling nuts (C) : 11.0 N·m (1.1 kg-m, 8 ft-lb)

2. Install the cooling fan (6) and tighten the fan bolts (B) to specifi-
cation.
AWBIA0602ZZ
Cooling fan bolts (B) : 8.0 N·m (0.8 kg-m, 71 in-lb)

3. Install the power steering pump belt, generator belt and the A/C compressor belt, if equipped. Refer to
EM-16, "Removal and Installation".
4. Install the front air duct.
Removal and Installation (Motor Driven Type) (Models with A/C) INFOID:0000000003941934
ALBIA0555GB
1. Cooling fan 2. Cooling fan shroud bracket (lower) 3. Cooling fan shroud
4. Cooling fan motor 5. Cooling fan shroud bracket (upper) A. Apply on cooling fan motor shaft
REMOVAL
1. Remove front grille. Refer to EI-15, "Removal and Installation".
2. Disconnect harness connector from cooling fan motor, and move it aside.
3. Remove cooling fan bolts and remove cooling fan assembly (motor driven type).
CAUTION:
Do not damage or scratch A/C condenser when removing.
INSTALLATION
• Cooling fan (motor driven type) is controlled by ECM. For details, refer to EC-227, "Diagnosis Procedure".

WATER PUMP
WATER PUMP
A
Removal INFOID:0000000003489899
CO
J
AWBIA0601GB
1. Water inlet 2. Thermostat 3. Water pump K

4. Water pump pulley 5. Fan coupling 6. Cooling fan
A. Front mark B. Follow installation procedure for Front
tightening sequence L
CAUTION:
• When removing water pump assembly, be careful not to get coolant on drive belts.
• Water pump cannot be disassembled and should be replaced as a unit. M
• After installing water pump, connect hose and clamp securely. Check for leaks using radiator cap
tester.
1. Remove engine undercover. N
2. Drain coolant from engine. Refer to CO-10, "Changing Engine Coolant".
3. Remove the front air duct.
4. Remove fan coupling with cooling fan. O
5. Remove power steering pump drive belt, generator drive belt, and A/C compressor drive belt, if equipped.
Refer to EM-16, "Removal and Installation".
6. Remove water pump pulley. P
7. Remove water pump.

WATER PUMP
Inspection INFOID:0000000003489900
• Check body assembly for rust or corrosion.

• Check for rough operation due to excessive end play.
SLC738
Installation INFOID:0000000003489901
1. Use a scraper to remove liquid gasket from water pump.

• Also remove traces of liquid gasket from mating surface
of cylinder block.
SLC188A
2. Apply a continuous bead of liquid gasket to mating surface of

water pump.
• Use Genuine Anaerobic Liquid Gasket or equivalent.
Refer to GI-43, "Recommended Chemical Product and
Sealant".
ALC078
3. Install water pump. Tighten water pump bolts to specification.

4. Install water pump pulley.
5. Loosely install power steering pump drive belt, generator drive belt, and A/C compressor drive belt, if
equipped. Refer to EM-15, "Checking Drive Belts".
6. Install the fan coupling (5) and tighten the fan coupling nuts (C)
to specification in the order as shown.
• (A): Front mark
• : Front
Fan coupling nuts (C) : 11.0 N·m (1.1 kg-m, 8 ft-lb)

7. Install the cooling fan (6) and tighten the cooling fan bolts (B) to
specification.
8. Adjust the power steering pump drive belt, generator drive belt AWBIA0602ZZ
and A/C compressor drive belt, if equipped. Refer to EM-15,
"Checking Drive Belts".
9. Install the front air duct.

WATER PUMP
10. Refill engine cooling system. Refer to CO-10, "Changing Engine Coolant".
11. Install the engine undercover. A
CO

THERMOSTAT
THERMOSTAT
Removal INFOID:0000000003489902
NOTE:
• Be careful not to spill coolant over engine compartment.
• Use a rag to absorb excess coolant.
1. Remove the engine undercover.
2. Drain coolant from engine. Refer to CO-10, "Changing Engine Coolant".
3. Remove air cleaner and air duct assembly.
4. Remove water hose from water inlet housing.
5. Remove water inlet housing bolts (A), water inlet housing (2)
and thermostat (1).
AWBIA0603ZZ
Inspection INFOID:0000000003489903
1. Check valve seating condition at normal room temperature. It

should seat tightly.
2. Check valve opening temperature and valve lift.
Valve opening temperature 76.5°C (170°F)

Valve lift More than 8 mm/90°C (0.31 in/194°F)
3. Check if valve closes at 5°C (9°F) below valve opening tempera-
ture.
SLC343
Installation INFOID:0000000003489904
1. Use a scraper to remove old liquid gasket from water inlet.

• Also remove traces of liquid gasket from mating surface of front cover.
2. Apply a continuous bead of liquid gasket to mating surface of
water inlet.
• Use Genuine Anaerobic Liquid Gasket or equivalent.
Refer to GI-43, "Recommended Chemical Product and
Sealant".
ALC088

THERMOSTAT
3. Install thermostat with jiggle valve or air bleeder at upper side.
A
CO
SLC097
D
4. Install water inlet housing (2) and tighten water inlet housing
bolts (A) to specification.
• (1): Thermostat
E
Water inlet housing : 7.3 N·m (0.74 kg-m, 65 in-lb)
bolts (A)
F
G
AWBIA0603ZZ
5. Install water hose to water inlet housing.

H
6. Install air cleaner and air duct assembly.
7. Refill engine cooling system. Refer to CO-10, "Changing Engine Coolant".
• After installation, run engine for a few minutes and check for leaks. Refer to CO-9, "System
Inspection". I
8. Install the engine undercover.

SERVICE DATA AND SPECIFICATIONS (SDS)
Standard and Limit INFOID:0000000003950084
ENGINE COOLANT CAPACITY

Unit: (US qt, lmp qt)
Engine coolant capacity

Approx 7.7 (8-1/8, 6-3/4)
(With reservoir tank at “MAX” level)
Reservoir tank 0.8 (7/8, 3/4)
THERMOSTAT
Valve opening temperature 76.5°C (170°F)

Valve lift More than 8 mm/90°C (0.31 in/194°F)
RADIATOR
Unit: kPa (bar, kg/cm2, psi)
Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)

Cap relief pressure
Limit 59 (0.59, 0.6, 9)
Leakage test pressure 157 (1.57, 1.6, 23)

PRECAUTIONS
< SERVICE INFORMATION > [YD25DDTi]
SERVICE INFORMATION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT CO
PRE-TENSIONER" INFOID:0000000003891694
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING: D
• 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 performed by
an authorized NISSAN/INFINITI dealer. E
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SRS section.
F
• 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 har-
ness connectors.
G
Precaution for Liquid Gasket INFOID:0000000003897588
REMOVAL OF LIQUID GASKET SEALING H

• After removing nuts and bolts, separate the mating surface, using Tool and remove old liquid gasket sealing.
Tool number : KV10111100 (J-37228)

I
CAUTION:
Be careful not to damage the mating surfaces.
• Tap (1) Tool to insert it, and then slide it (2) by tapping on the side
J
as shown.
• In areas where Tool is difficult to use, use plastic hammer to lightly
tap the parts, to remove it.
CAUTION: K
If for some unavoidable reason suitable tool such as screw-
driver is used, be careful not to damage the mating surfaces. WBIA0566E
LIQUID GASKET APPLICATION PROCEDURE L

1. Remove old liquid gasket adhering to the liquid gasket applica-
tion surface and the mating surface, Using scraper.
• Remove liquid gasket completely from the groove of the liquid M
gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials. N
O
PBIC0003E

PRECAUTIONS
3. Attach liquid gasket tube to Tool.
Tool number : WS39930000 ( — )

Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-43, "Recommended Chemical Product and Sealant".
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions.
WBIA0567E
• If there is a groove for the liquid gasket application, apply liq-

uid gasket to the groove.
• 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.
• Within five minutes of liquid gasket application, install the mat-
ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Do not retighten nuts or bolts after the installation.
• After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
SEM159F
CAUTION:
If there are specific instructions in this manual, observe them.

PREPARATION
PREPARATION
A
Special Service Tool INFOID:0000000003511244
CO
Tool number Description
(Kent-Moore No.)
Tool name
C
WS39930000 Pressing the tube of liquid gasket.
( — )
Tube presser
D
E
S-NT052
EG17650301 Adapting radiator cap tester to radiator cap

(J-33984-A) and radiator filler neck.
Radiator cap tester adapter a: 28 (1.10) dia. F
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
G
S-NT564
KV10111100 Removing water inlet, water outlet and ther- H

(J-37228) mostat housing.
Seal cutter
NT046
J
Commercial Service Tool INFOID:0000000003511245
K
Tool name Description
Power tool Loosening bolts and nuts.
L
PBIC0190E
Radiator cap tester Checking radiator and reservoir tank cap. N
PBIC1982E
P

Troubleshooting Chart INFOID:0000000003511246
Symptom Check items

Water pump malfunction Worn or loose drive belt
Thermostat stuck closed —
Dust contamination or pa-
Poor heat transfer Damaged fins per clogging —
Physical damage
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
Refer to EC-575
ate
Reduced air flow High resistance to fan rota- —
tion Fan assembly
Damaged fan blades
Damaged radiator shroud — Radiator shroud —
Improper engine coolant
Cooling sys- — Engine coolant mixture ratio —
mixture ratio
tem parts
malfunction Poor engine coolant quality — Engine coolant density —
Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Loose
Radiator cap
Poor sealing
Engine coolant leaks
O-ring for damage, deterio-
Insufficient engine coolant ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leaks into cool-
Overflowing reservoir tank Cylinder head gasket deteri-
ing system
oration

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

COOLING SYSTEM
COOLING SYSTEM
Cooling Circuit INFOID:0000000003511247
TYPE 1 Models Without EGR
AWBIA0606ZZ
1. Radiator 2. Water pump 3. Thermostat

4. Oil cooler 5. Turbocharger 6. Water inlet

COOLING SYSTEM
7. Thermostat housing 8. Cylinder block 9. Cylinder head
10. Water outlet 11. Reservoir tank 12. Heater feed pipe A
13. Heater core 14. Heater return pipe A. To heater core
B. From cylinder block C. From cylinder block D. From heater core
E. Coolant passage in cylinder block F. Coolant passage in cylinder head G. When thermostat is closed CO
H. When thermostat is open
TYPE 1 Models With EGR C
AWBIA0605ZZ

COOLING SYSTEM
1. Radiator 2. Water pump 3. Thermostat

4. Oil cooler 5. Turbocharger 6. Water inlet
7. Thermostat housing 8. Cylinder block 9. Cylinder head
10. Water outlet 11. Reservoir tank 12. EGR volume control valve
13. Heater feed pipe 14. Heater core 15. Heater return pipe
A. To heater core B. To EGR volume control valve C. From cylinder block
D. From cylinder block E. From heater core F. From EGR volume control valve
G. Coolant passage in cylinder block H. Coolant passage in cylinder head J. When thermostat is closed
K. When thermostat is open

COOLING SYSTEM
TYPE 2 Models With EGR
A
CO
JPBIA2191GB

ENGINE COOLANT
ENGINE COOLANT
System Inspection INFOID:0000000003901237
WARNING:
• Never remove the radiator cap when the engine is hot. Serious burns could occur from high pres-
sure coolant escaping from the radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter turn to allow built-up pressure to
escape. Carefully remove the radiator cap by turning it all the way.
LEVEL CHECK
• Check if the reservoir tank engine coolant level is within MIN to
MAX when engine is cool.
• Refill engine coolant if necessary. Refer to CO-33, "Changing
Engine Coolant".
SMA412B
CHECKING COOLING SYSTEM HOSES

• Check hoses for improper attachment, leaks, cracks, damage, chafing and deterioration.
CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follows:
CAUTION:
• When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radia-
tor shroud and horns.
• Tape the harness 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 water flows clear coming out of the radiator.
4. Blow air into the back side of radiator core vertically downward.
• Use compressed air lower than 490 kPa (5 kg/cm2, 71 psi) and keep the air hose end more than 30 cm
(11.8 in) away from the core.
5. Blow air again into all the radiator core surfaces once per minute until no water blows out and the core is
dry.
CHECKING COOLING SYSTEM FOR LEAKS
• To check for leakage, apply pressure to the cooling system with a
suitable tool and Tool.
CAUTION:
Higher test pressure than specified may cause cooling sys-
tem damage.
Testing pressure : 157 kPa (1.57 bar, 1.6 kg/cm2,

23 psi)
Tool number : EG17650301 (J-33984-A)

SLC756A
• If anything is found, repair or replace damaged parts.

CHECKING RADIATOR CAP

ENGINE COOLANT
• To check radiator cap, apply pressure to radiator cap with a suit-
able tool and Tool. A
Radiator cap relief pressure

Standard : 98 - 118 kPa (0.98 - 1.18 bar, 1.0 - 1.2 kg/ CO
cm2, 14 - 17 psi)
C
Tool number : EG17650301 (J-33984-A)

SLC755A
D
• Pull the negative pressure valve to open it.
Check that it closes completely when released.
E
G
SMA967B
Changing Engine Coolant INFOID:0000000003901238

H
WARNING:
• To avoid being scalded, do not change engine coolant when engine is hot.
• Wrap a thick cloth around cap and carefully remove cap. First, turn cap a quarter of a turn to release I
built-up pressure. Then turn cap all the way.
• Be careful not to allow engine coolant to contact drive belts.
DRAINING ENGINE COOLANT J
1. Open radiator drain plug at the bottom of radiator, and remove radiator cap.
CAUTION:
Be careful not to allow engine coolant to contact drive belts. K
When draining all engine coolant in the system, also perform the following steps.
L
2. Open cylinder block drain plug. Refer to EM-179, "Component".
3. Remove reservoir tank, drain engine coolant, then clean reservoir tank.
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
M
If contaminated, flush engine cooling system.
REFILLING ENGINE COOLANT
1. Install reservoir tank. N
• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-179,
"Component".
2. Install the radiator drain plug. O
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring.
P
Radiator drain plug: : 1.2 N·m (0.12 kg-m, 11 in-lb)
3. Make sure that each hose clamp has been firmly tightened.

ENGINE COOLANT
4. Fill radiator and reservoir tank to the specified level.
• Pour engine coolant through engine coolant filler neck
slowly of less than 2 (2-1/8 US qt, 1-3/4 lmp qt) a minute
to allow air in system to escape.
• Use Genuine Nissan Engine Coolant or equivalent mixed
with water (distilled or demineralized). Refer to MA-12,
"Engine Coolant Mixture Ratio".
Engine coolant capacity : Approx. 9.4 (10.0 US qt, 8-

(with reservoir tank at 1/4 lmp qt)
“MAX” level) SMA182B
Reservoir tank capacity : 0.8 (7/8 US qt, 3/4 lmp qt)

(at “MAX” level)
• When engine coolant overflows air relief hole, install air relief
plug and install the radiator cap.
SMA412B
5. Start engine and warm it up until it reaches normal operating temperature (10 minutes maximum).
• If engine coolant overflows radiator filler hole, install radiator cap.
6. Keep racing at 2000-2500 rpm and refill through reservoir tank filler until engine coolant level stabilizes on
MAX. Close reservoir tank cap and continue warm up until thermostat is opened (check the radiator
hose).
CAUTION:
Watch engine coolant temperature gauge so as not to overheat the engine.
7. Stop the engine. After it has completely cooled down (using a fan to reduce the time), start engine and
keep it at idling.
8. Check the engine coolant level and refill engine coolant only through reservoir tank filler.
9. If the engine coolant level lowered, repeat steps 4 through 7 checking that engine coolant level on reser-
voir tank is stabilized on MAX.
10. Check cooling system for leaks with engine running.
11. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000
rpm with heater temperature controller set at several position between COOL and WARM.
• Sound may be noticeable at heater unit.
12. Repeat step 11 three times.
13. If sound is heard, bleed air from cooling system by repeating steps 4 through 7 until engine coolant level
no longer drops.
FLUSHING COOLING SYSTEM
1. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and
reservoir tank with water and reinstall radiator cap and reservoir tank cap.
2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down.
5. Drain water from the system. Refer to CO-33.
6. Repeat steps 1 through 5 until clear water begins to drain from radiator.

RADIATOR
RADIATOR
A
CO
ALBIA0554GB
1. Radiator mounting bracket (upper) 2. Radiator filler cap 3. Radiator mounting rubber (upper) K
4. Radiator seal (upper) 5. Radiator 6. Radiator seal (lower)
7. Radiator mounting rubber (lower) 8. Radiator drain plug O-ring 9. Radiator drain plug
L
10. Radiator hose clamps (lower) 11. Radiator hose (lower) 12. Radiator hose clamps (upper)
13. Radiator hose (upper) 14. Radiator shroud (upper) 15. Radiator shroud (lower)
16. Reservoir tank 17. Reservoir tank hose clamps 18. Reservoir tank hose
M
19. Reservoir tank filler cap Front

N
WARNING:
from high-pressure engine coolant escaping from radiator and/or reservoir tank. O
REMOVAL
P
2. Drain engine coolant from radiator. Refer to CO-33, "Changing Engine Coolant".
CAUTION:
3. Disconnect reservoir tank hose and remove reservoir tank.
4. Disconnect radiator hose (upper and lower).
CAUTION:

RADIATOR
Do not spill engine coolant on drive belts.
5. Remove radiator shroud (lower).
6. Remove radiator shroud (upper).
7. Remove radiator mounting brackets (upper).
8. Remove radiator.
CAUTION:
Do not damage or scratch A/C condenser (if equipped) and radiator core when removing.
Checking Reservoir Tank Cap
• Inspect valve seat of reservoir tank cap.
- Check if valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
- Check if valve seat has no soil and damage.
PBIC2816E
• Pull negative-pressure valve to open it, and make sure that it is

completely closed when released.
- Make sure that there is no dirt or damage on the valve seat of radi-
ator cap negative-pressure valve.
- Make sure that there are no unusualness in the opening and clos-
ing conditions of negative-pressure valve.
SMA967B
• Check reservoir tank cap relief pressure.
Standard : 98 - 118 kPa (0.98 - 1.18 bar, 1.0 - 1.2 kg/

cm2, 14 - 17 psi)
- When connecting reservoir tank cap to the Tool and the radiator
cap tester, apply engine coolant to the cap seal surface.
Tool number : EG17650301 (J-33984-A)

SLC755AC
• Replace reservoir tank cap if there is an unusualness in negative pressure valve, or if the relief pressure falls
below the limit.
CAUTION:
When installing a radiator cap and reservoir tank cap, thoroughly wipe out the radiator and reservoir
tank filler neck to remove any waxy residue or foreign material.
Checking Radiator
Check radiator for mud or clogging. If necessary, clean radiator as follows.
NOTE:
• 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.

RADIATOR
1. Apply water by hose to the back side of the radiator core vertically downwards.
2. Apply water again to all radiator core surface once per minute. A
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downwards.
NOTE: CO
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71 psi) and keep distance more than 30 cm
(11.8 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out. C
INSTALLATION
D
• Check for leaks of engine coolant using the Tool and the radiator cap tester. Refer to CO-32, "System
Inspection". E
Tool number : EG17650301 (J-33984-A)

• Start and warm up engine. Visually check if there is no leaks of engine coolant. F

COOLING FAN
COOLING FAN
Component (Crankshaft Driven Type) INFOID:0000000003511255
PBIC4056E
1. Cooling fan 2. Fan coupling 3. Water pump pulley

4. Water pump A. Front mark
REMOVAL
CAUTION:
• Do not release the drive belt tension by removing the fan/water pump pulley.
• Fan coupling cannot be disassembled and should be replaced as a unit. If front mark F is present,
install fan so that side marked F faces the front.
1. Remove drive belts. Refer to EM-89, "Removal and Installation".
2. Loosen and remove radiator shroud (upper) bolts. Refer to CO-35, "Component".
3. Move radiator shroud (upper) toward engine, and remove cooling fan bolts and cooling fan (crankshaft
driven type).
CAUTION:
Do not damage or scratch radiator core when removing.
4. Remove fan coupling nuts, fan coupling and water pump pulley, if necessary.
WARNING:
When the engine is running, keep hands and clothing away from moving parts such as drive belts and
cooling fan.
Fan Coupling
• Check fan coupling for rough operation, wobbling, oil leakage or
bent bimetal fins.
SLC072

COOLING FAN
• After assembly, verify the cooling fan does not wobble or flap while A
the engine is running.
CO
SLC151B
D
INSTALLATION
• Install cooling fan with its front mark facing front of engine. E
CAUTION:
• Install the drive belt only after the fan and fan coupling to water pump flange bolts/nuts have been
properly tightened.
• Proper alignment of these components is essential. Improper alignment will cause them to wobble F
and may eventually cause the fan to separate from the water pump, causing extensive damage.
Removal and Installation (Motor Driven Type) (Models with A/C) INFOID:0000000003511257
G
ALBIA0555GB
M
1. Cooling fan 2. Cooling fan shroud bracket (lower) 3. Cooling fan shroud
4. Cooling fan motor 5. Cooling fan shroud bracket (upper) A. Apply on cooling fan motor shaft
N
REMOVAL
1. Remove front grille. Refer to EI-15, "Removal and Installation".
2. Disconnect harness connector from cooling fan motor, and move it aside. O
3. Remove cooling fan bolts and remove cooling fan assembly (motor driven type).
CAUTION:
Do not damage or scratch A/C condenser when removing. P
INSTALLATION
• Cooling fan (motor driven type) is controlled by ECM. For details, refer to EC-575, "Component Inspection".

WATER PUMP
WATER PUMP
PBIC4057E
1. Gasket 2. Water pump 3. Water pump pulley

4. Fan coupling
WARNING:
Do not remove radiator cap and/or reservoir tank cap when the engine is hot. Serious burns could
occur from high pressure engine coolant escaping from the radiator and/or the reservoir tank.
CAUTION:
• When removing water pump assembly, do not get engine coolant on drive belts.
• Water pump cannot be disassembled and should be replaced as a unit.
• After installing water pump, connect hose and clamp securely, then check for leaks.
REMOVAL
2. Drain engine coolant. Refer to CO-33, "Changing Engine Coolant".
CAUTION:
3. Remove drive belts. Refer to EM-89, "Removal and Installation".
4. Remove cooling fan (crankshaft driven type), cooling fan coupling and water pump pulley. Refer to CO-38,
"Removal and Installation".
5. Remove water pump bolts and the water pump.
• Engine coolant will leak from cylinder block, so have a receptacle ready below.
CAUTION:
• Handle the water pump vane so that it does not contact any other parts.
• Water pump cannot be disassembled and should be replaced as a unit.

WATER PUMP
• Visually check if there is no significant dirt or rusting on the water A
pump body and vane.
• Make sure that there is no looseness in the vane shaft, and that it
turns smoothly when rotated by hand. CO
• If there are any unusualness, replace water pump assembly as
necessary.
PBIC3354E D
INSTALLATION
• Installation is in the reverse order of removal.
• Install cooling fan (crankshaft driven type) with the front mark facing the front of engine. Refer to CO-38, E
"Component (Crankshaft Driven Type)".
F
• Check for leaks of engine coolant using Tool and the radiator cap tester. Refer to CO-32, "System Inspec-
tion".
Tool number : EG17650301 (J-33984-A) G
H

THERMOSTAT AND WATER PIPING
TYPE 1 Models Without EGR
AWBIA0608GB
1. Engine coolant temperature sensor 2. Gasket 3. Water outlet

4. Clamp 5. Water hose 6. Gasket
7. Thermostat housing 8. Rubber ring 9. Thermostat
10. Water inlet 11. Gasket 12. Clamp
13. Water hose 14. Heater return pipe 15. Water hose
16. Clamp 17. Heater feed pipe A. To heater core
B. To cylinder head C. To radiator D. To turbocharger
E. To oil cooler

A
CO
L
AWBIA0607GB
1. Engine coolant temperature sensor 2. Gasket 3. Water outlet M

4. Clamp 5. Water hose 6. Gasket
7. Thermostat housing 8. Rubber ring 9. Thermostat
10. Water inlet 11. Gasket 12. Clamp N
13. Water hose 14. Heater return pipe 15. Water hose
16. Clamp 17. Clamp 18. Water hose
19. Heater feed pipe A. To heater core B. To cylinder head O
C. To EGR control valve D. To radiator E. To turbocharger
F. To oil cooler
P

JPBIA2192GB
1. Engine coolant temperature sensor 2. Gasket 3. Clamp

4. Water hose 5. Water outlet 6. Clamp
7. Water hose 8. Gasket 9. Thermostat housing
10. Rubber ring 11. Thermostat 12. Water inlet
13. Gasket 14. Clamp 15. Water hose
16. Heater return pipe 17. Water hose 18. Clamp
19. Clamp 20. Water hose 21. Heater feed pipe
A. To heater core B. To EGR cooler C. To EGR control valve
D. To radiator E. To turbocharger F. To oil cooler
WARNING:
from high pressure engine coolant escaping from radiator and/or reservoir tank.
REMOVAL

2. Drain engine coolant from radiator, and from water drain plug at the side of cylinder block. Refer to CO-33, A
"Changing Engine Coolant" and EM-179, "Component".
CAUTION:
Perform this step when engine is cold. CO
3. Disconnect radiator hoses (upper and lower) from engine side. Refer to CO-35, "Component".
4. Remove air hose between charge air cooler and turbocharger and air duct between air cleaner case and
turbocharger. Refer to EM-92, "Component" and EM-90, "Component". C
5. Remove water outlet, water inlet and thermostat.
6. Remove thermostat housing.
7. Disconnect heater return hose and water hoses at heater return pipe side, and remove heater return pipe. D
8. Remove oil level gauge guide bolt, vacuum hoses (to turbocharger boost control solenoid valve) and spill
hose. Refer to EM-108, "Component", EM-93, "Component" and EM-117, "Component".
9. Disconnect water hoses (to EGR cooler, if equipped), vacuum hoses and heater feed hose at heater feed E
pipe side, and remove heater feed pipe.
F
Thermostat
• Place a string so that it is caught in the valves of the thermostat.
Immerse fully in a container filled with water. Heat while stirring.
G
• The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
• Continue heating. Check the full-open lift amount.
• After checking the full-open lift amount, lower the water tempera- H
ture and check the valve closing temperature.
SLC252B
Standard values J
Item Thermostat
Valve opening temperature 80.5 - 83.5°C (177 - 182° F)
Full-open lift amount More than 9 mm/ 95°C (0.35 in/ 203 °F) K
Valve closing temperature More than 77°C (171°F)
• If out of the standard, replace thermostat. L
INSTALLATION
• Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge. M
• When inserting heater feed pipe end into cylinder head, apply a neutral detergent to O-ring. Then insert it
immediately.
• Install the thermostat with the whole circumference of each flange
N
part fit securely inside the rubber ring.
• Install the thermostat with the jiggle valve facing upwards.
JLC300B

• Check for leaks of engine coolant using Tool and the radiator cap tester. Refer to CO-32, "System Inspec-
tion".

Tool number : EG17650301 (J-33984-A)


A
Standard and Limit INFOID:0000000003511262
ENGINE COOLANT CAPACITY CO

Unit: (US qt, lmp qt)
Engine coolant capacity

Approx 9.4 (10.0, 8-1/4) C
(With reservoir tank at “MAX” level)
Reservoir tank 0.8 (7/8, 3/4)
THERMOSTAT D
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)

Full open lift amount More than 9 mm/ 95°C (0.35 in/203°F) E
Valve closing temperature More than 77°C (171°F)
RESERVOIR TANK
F
Unit: kPa (bar, kg/cm2, psi)
Standard 98 - 118 (0.98 - 1.18, 1.0 - 1.2, 14 - 17)

Cap relief pressure
Limit 78 (0.78, 0.8, 11) G
Leakage test pressure 157 (1.57, 1.6, 23)

Engine Cooling System: Section

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ENGINE

Revision: March 2008 CO-1 2009 D22 LCV

Revision: March 2008 CO-2 2009 D22 LCV

REMOVAL OF LIQUID GASKET SEALING H

Tool number : KV10111100 (J-37228)

LIQUID GASKET APPLICATION PROCEDURE L

Revision: March 2008 CO-3 2009 D22 LCV

Tool number : WS39930000 ( — )

• If there is a groove for the liquid gasket application, apply liq-

Revision: March 2008 CO-4 2009 D22 LCV

EG17650301 Adapting radiator cap tester to radiator filler

KV10111100 Removing water pump and water inlet hous- H

Radiator cap tester Checking radiator and reservoir tank cap. N

Revision: March 2008 CO-5 2009 D22 LCV

Symptom Check items

Revision: March 2008 CO-6 2009 D22 LCV

Installed large fog lamp

Revision: March 2008 CO-7 2009 D22 LCV

Revision: March 2008 CO-8 2009 D22 LCV

Tool number : EG17650301 (J-33984-A) P

CHECKING RADIATOR CAP

Revision: March 2008 CO-9 2009 D22 LCV

Radiator cap relief pressure

Tool number : EG17650301 (J-33984-A)

• Pull the negative pressure valve to open it.

Changing Engine Coolant INFOID:0000000003901233

Radiator drain plug: : 1.2 N·m (0.12 kg-m, 11 in-lb)

Revision: March 2008 CO-10 2009 D22 LCV

Engine coolant capacity : Approx. 7.7 (8-1/8 US qt, C

Reservoir tank capacity : 0.8 (7/8 US qt, 3/4 lmp qt)

Revision: March 2008 CO-11 2009 D22 LCV

Removal and Installation INFOID:0000000003489906

Revision: March 2008 CO-12 2009 D22 LCV

• Check reservoir tank cap relief pressure. L

Standard : 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/

Tool number : EG17650301 (J-33984-A)

Revision: March 2008 CO-13 2009 D22 LCV

Tool number : EG17650301 (J-33984-A)

Revision: March 2008 CO-14 2009 D22 LCV

INSPECTION AFTER REMOVAL H

Revision: March 2008 CO-15 2009 D22 LCV

Fan coupling nuts (C) : 11.0 N·m (1.1 kg-m, 8 ft-lb)

Cooling fan bolts (B) : 8.0 N·m (0.8 kg-m, 71 in-lb)

Revision: March 2008 CO-16 2009 D22 LCV

1. Water inlet 2. Thermostat 3. Water pump K

Revision: March 2008 CO-17 2009 D22 LCV

• Check body assembly for rust or corrosion.

1. Use a scraper to remove liquid gasket from water pump.

2. Apply a continuous bead of liquid gasket to mating surface of

3. Install water pump. Tighten water pump bolts to specification.

Fan coupling nuts (C) : 11.0 N·m (1.1 kg-m, 8 ft-lb)

Revision: March 2008 CO-18 2009 D22 LCV

Revision: March 2008 CO-19 2009 D22 LCV

1. Check valve seating condition at normal room temperature. It

Valve opening temperature 76.5°C (170°F)

1. Use a scraper to remove old liquid gasket from water inlet.

Revision: March 2008 CO-20 2009 D22 LCV

5. Install water hose to water inlet housing.

Revision: March 2008 CO-21 2009 D22 LCV

ENGINE COOLANT CAPACITY

Engine coolant capacity

Valve opening temperature 76.5°C (170°F)

Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)