ENGINE COOLING SYSTEM

B ENGINE

ENGINE COOLING SYSTEM

SECTION CO CO

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

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

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

REMOVAL OF LIQUID GASKET SEALING

● 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
● 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
● 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.
● If there is a groove for the liquid gasket application, apply the J
gasket to the groove.

L
EMA0622D

● 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.
● Within five minutes of gasket application, install the mating com-
ponent.
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten after the installation.
● After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION: SEM164F
If there are additional instructions in this manual, observe them.

CO-3
 PREPARATION
[CR]
PREPARATION PFP:00002

Special Service Tools EBS00OJJ

NISSAN Tool number

(RENAULT tool number) Description
Tool name

WS39930000 Pressing the tube of liquid gasket

( — )
Tube presser

S-NT052

EG17650301 Adapting radiator cap tester to radiator filler

( — ) neck
Radiator cap tester adapter a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

S-NT564

KV99103510 Installing radiator upper and lower tanks

( — )
Radiator plate pliers A

S-NT224

KV99103520 Removing radiator upper and lower tanks

( — )
Radiator plate pliers B

S-NT225

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

MLIA0012E

— Adapting tester to reservoir tank

(M.S. 554_01)
Reservoir tank tester adapter

MLIA0013E

— Adapting tester to reservoir tank cap

(M.S. 554_06)
Reservoir tank cap tester adapter

MLIA0014E

CO-4
 PREPARATION
[CR]
Commercial Service Tool EBS01JAW

A
Tool name Description

Radiator cap tester Checking radiator and radiator cap

CO

PBIC1982E

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

Troubleshooting Chart EBS00OIR

Symptom Check items

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

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

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

Cooling Circuit EBS00OIS

PBIC1475E

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

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

E
SMA412B

M/T Models with A/C

● Check if the reservoir tank coolant level is within MIN to MAX when engine is cool. F
● Adjust coolant if too much or too little.
Vehicle front
G

MBIB1360E
J

M
MBIA0092E

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

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

MBIB1362E

● Warm up the engine and turn it off.

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

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

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

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

E
MBIB1360E

REFILLING ENGINE COOLANT

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

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

Engine coolant capacity

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

SMA412B

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

: Vehicle front

MBIB1360E

MBIA0092E

5. Warm up engine to normal operating temperature with radiator cap installed.

6. Warm up until thermostat opens. Keep warming at 3,000 rpm for approximately 10 minutes as guide.
● For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot.

CAUTION:
Be careful not to overheat.
7. Stop the engine.
8. After cooling engine [approximately 50°C (122 °F) or lower], remove radiator cap and check coolant level.
If the level is low, fill up to the radiator neck again and repeat from step 5.
9. When the coolant level stabilizes, fill reservoir tank up to the “MAX” line.
10. Check cooling system for leaks with engine running.
11. Allow the engine to cool [approximately 50°C (122°F) or lower].
12. Start the engine. Perform the following cycle three times. Keep an engine speed of 1,000 rpm for approxi-
mately 30 seconds. Then increase it gradually to 3,000 rpm.
13. During the above step 12, make sure water flow sound is not heard from heater core.
● Sound may be noticeable at heater unit.

14. If water flow sound is heard, repeat from step 4 to 13.

● Clean excess coolant from engine.

FLUSHING COOLING SYSTEM

1. Fill radiator and reservoir tank with water and reinstall radiator 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.
6. Repeat steps 1 through 5 until clear water begins to drain from radiator.

CO-12
 RADIATOR
[CR]
RADIATOR PFP:21400
A
Removal and Installation EBS00OIW

CO

PBIC1478E
K
1. Cooling fan assembly 2. Hose clamp 3. Radiator hose (upper)
4. Radiator 5. Radiator cap 6. Mounting rubber
7. Mounting rubber 8. Hose clamp (A/T models) 9. A/T oil cooler hose (A/T models) L
10. Hose clamp (A/T models) 11. Hose clamp (A/T models) 12. A/T oil cooler hose (A/T models)
13. Hose clamp 14. Radiator hose (lower) 15. Bracket
16. Hose clamp 17. reservoir tank cap 18. Reservoir tank M
19. Reservoir tank hose

CO-13
 RADIATOR
[CR]

PBIC1479E

1. Radiator 2. Mounting rubber 3. Radiator hose (upper)

4. Hose clamp 5. Reserve tank cap 6. Hose clamp
7. Reservoir tank hose 8. Reservoir tank 9. Cooling fan assembly
10. Hose clamp 11. Radiator hose (lower) 12. Hose clamp
13. Reservoir tank hose 14. Mounting rubber

REMOVAL
Operation Description: Remove radiator core support (lower), and pull out radiator and cooling fan assembly
to the underside of vehicle.
1. Drain coolant. Refer to CO-9, "ENGINE COOLANT" .
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pres-
sure coolant escaping from the radiator.
2. Remove mounting bolts to make relay case movable.
3. Remove the following parts.
● Reservoir tank (M/T models with A/C)

● RH/LH front fender protector

● RH/LH front grille; Refer to EI-11, "FRONT GRILLE" .

● Air Duct; Refer to EM-18, "AIR CLEANER AND AIR DUCT" .

4. Remove radiator hose (upper) and (lower).

5. Remove A/T oil cooler hoses. (A/T models)
CAUTION:
Install plug to hoses and fluid pipes removed, and be sure to prevent fluid leak.

CO-14
 RADIATOR
[CR]
6. Fix with ropes so that A/C condenser and RH/LH upper mount
units of radiator and cooling fan assembly are placed on radiator A
core support (upper).
CAUTION:
Taking parts strength into consideration, lift up at locations CO
where damage may not occur.

PBIC1480E

D
Remove radiator core support (lower) with the following proce-
dures.
a. Remove air guide upper clips at radiator right side. E
NOTE:
In figure, bumper fascia is omitted for explanation.
b. Remove radiator core support (lower) mounting bolts (RH/LH). F
Refer to BL-13, "RADIATOR CORE SUPPORT" .
c. Remove air guide lower clips and remove radiator core support
(lower). G
PBIC1481E

7. Loosen ropes, and pull out radiator and cooling fan assembly to H
the underside of vehicle, supporting the bottom with suitable
jack.
CAUTION: I
Be careful not to damage radiator core and A/C condenser
core.
J

PBIC1482E K

8. Remove reservoir tank (M/T models without A/C and A/T mod-
els). L
● Disconnect the reservoir tank from fan shroud to remove.
With force applied in the left direction of vehicle, pull up reser-
voir tank.
M

PBIC1476E

9. Remove cooling fan assembly from radiator.

CO-15
 RADIATOR
[CR]
INSTALLATION
Install in the reverse order of removal which being careful of the following.
● When installing radiator core support (lower), make sure upper and lower mount units of radiator and A/C
condenser are fitted in mounting holes of radiator core support (upper/lower).
Disassembly and Assembly of Cooling Fan EBS00OIY

MBIB1359E

1. Resistor 2. Fan shroud 3. Fan motor

4. Fan

PBIC1484E

1. Fan shroud 2. Fan motor 3. Fan

CO-16
 RADIATOR
[CR]

CO

F
PBIC1485E

1. Resistor 2. Fan shroud 3. Fan motor

4. Fan
G

DISASSEMBLY
1. Remove fan. H
CAUTION:
Reverse screw are used for the fan attachment screw.When
removing or attaching, turn the screw the opposite way as I
for a normal screw.
2. Remove fan motor from fan shroud.
J

PBIC1486E
K

ASSEMBLY
Assemble cooling fan in the reverse order of disassembly. L
● Apply thread locking sealant and tighten screw to assemble the fan.
Checking Radiator Cap (M/T Models without A/C and A/T Models) EBS01KBX
M
1. Pull the negative-pressure valve to open it and check that it closes completely when released.
● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve.

● Check that there are no unusual conditions in the opening

and closing conditions of the negative-pressure valve.

SMA967B

CO-17
 RADIATOR
[CR]
2. Check radiator cap relief pressure.
Standard:
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2 , 11 - 14 psi)
Limit:
59 kPa (0.59 bar, 0.6 kg/cm2 , 9 psi)
● When connecting the radiator cap to the tester, apply water or
engine coolant to the cap seal part.
● Replace the radiator cap if there is an unusual conditions in
SLC135B

the negative-pressure valve, or if the open-valve pressure is

outside of the standard values.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy resi-
due or foreign material.
Checking Reservoir Tank Cap (M/T Models with A/C) EBS01KBY

● Fit the adapter to the tester as shown.

● When connecting the reservoir tank cap to the tester, apply
water or LLC to the cap seal part.
● Check reservoir tank cap relief pressure.

88 kPa (0.88 bar, 0.90 kg/cm2 , 12.8 psi)

● Replace the reservoir tank cap if the engine coolant passes
through it, or if any fur signs is detected.

MBIB1079E

Checking Cooling System Hoses EBS00OSF

Check hoses for improper attachment, leaks, cracks, damage, loose connections, chaffing and deterioration.

CO-18
 RADIATOR (ALUMINUM TYPE)
[CR]
RADIATOR (ALUMINUM TYPE) PFP:21460
A
Disassembly and Assembly EBS00OJ0

CO

SLC882AB
G

PREPARATION
1. Attach the spacer to the tip of the radiator plate pliers A. H
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 radiator plate pliers A are closed dimen-
I
sion H′′ is approx. 7.6 mm (0.299 in).
3. Adjust dimension H′′ with the spacer, if necessary.
J

SLC655C K
DISASSEMBLY
1. Remove tank with radiator plate pliers B (SST).
L

SLC903

CO-19
 RADIATOR (ALUMINUM TYPE)
[CR]
● Grip the crimped edge and bend it upwards so that Tool slips
off.
CAUTION:
Do not bend excessively.

SLC893

● In areas where Tool cannot be used, use a screwdriver to

bend the edge up.
CAUTION:
Be careful not to damage tank.

SLC930

2. Make sure the edge stands straight up.

3. Remove oil cooler from tank. (A/T model only)

SLC931

ASSEMBLY
1. Install oil cooler. (A/T model only)
CAUTION:
Pay attention to direction of conical washer.

SLC894

CO-20
 RADIATOR (ALUMINUM TYPE)
[CR]
2. Clean contact portion of tank.
A

CO

SLC932

D
3. Install sealing rubber.
CAUTION:
Be careful not to twist sealing rubber. E
NOTE:
Push it in with fingers.
F

G
SLC917A

4. Caulk tank in specified sequence with radiator plate pliers A H

(SST).

SLC904
K

SLC896

● Use pliers in the locations where Tool cannot be used.

SLC897

CO-21
 RADIATOR (ALUMINUM TYPE)
[CR]
5. Make sure that the rim is completely crimped down.
Standard height “H” : 8.0 - 8.4 mm (0.315 - 0.331 in)
6. Confirm that there is no leakage.
Refer to CO-9, "Inspection" .

SLC554A

INSPECTION
1. Apply pressure with radiator cap tester.
Specified pressure value
: 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler to seal its inlet and outlet. (A/T
model only)
SLC933

2. Check for leakage by soaking radiator in water container.

SLC934

CO-22
 WATER PUMP
[CR]
WATER PUMP PFP:21020
A
Removal and Installation EBS00OJ1

CO

PBIC1487E

1. Water pump pulley 2. Water pump 3. O-ring J

4. Water suction pipe 5. Heater hose 6. Radiator hose (lower)

REMOVAL K
1. Drain engine coolant. Refer to CO-9, "ENGINE COOLANT" .
CAUTION:
Make sure to drain when the engine coolant temperature is cold. L
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pres-
sure coolant escaping from the radiator. M
2. Steer front wheel to the right.
3. Remove front fender protector (RH). Refer to EI-14, "FENDER PROTECTOR" .
4. Loosen mounting bolts of water pump pulley before loosening belt tension of drive belt.
5. Remove drive belt from water pump pulley. Refer to EM-14, "DRIVE BELTS" .
6. Remove the water pump pulley.
NOTE:
To remove it easily, loosen water pump pulley mounting bolt, then water pump belt.
7. Remove water pump.
● Place a piece of wood or something onto water pump, and tap it with a hammer. Disconnect liquid gas-
ket to remove.
● Engine coolant remaining in the engine is drained. Use tray to collect it.

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.

8. Remove water suction pipe in the following procedures.

CO-23
 WATER PUMP
[CR]
a. Remove air cleaner case assembly. Refer to EM-18, "AIR CLEANER AND AIR DUCT" .
b. Remove radiator hose (upper and lower), and heater hose.
c. Move harnesses around suction pipe.
d. Remove mounting bolts, and pull water suction pipe toward engine rear side.
● Coolant remaining in the engine is drained. Use tray to collect it.

INSPECTION AFTER REMOVAL

● Visually check that there is no significant dirt or rusting on the
water pump body and vane.
● Check that there is no looseness in the vane shaft, and that it
turns smoothly when rotated by hand.
● If unusualness is found, replace the water pump.

PBIC1488E

INSTALLATION
● Install in the reverse order of removal which being careful of the following.
Water Suction Pipe Installation
1. Apply neutral detergent on O-ring. Fit O-ring in the groove
securely.
2. Tighten mounting bolts with the following procedures.
a. Temporarily tighten bolts in order: A to B.
b. Tighten bolts in order: B to A

PBIC1489E

Water Pump Installation

● Apply liquid gasket as shown in figure, and install.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
Wait at least 30 minutes after water pump installation. Refill
coolant and start the engine.

PBIC1490E

INSPECTION AFTER INSTALLATION

● Check for engine coolant leaks using radiator cap tester adapter (SST: EG17650301) and radiator cap
tester (commercial service tool) (M/T models without A/C and A/T models) or reservoir tank cap tester and
reservoir cap tester adapter (M/T models with A/C). Refer toCO-9, "LEAK CHECK"
.
● Start and warm up engine. Visually check if there is no leaks of engine coolant.

CO-24
 THERMOSTAT
[CR]
THERMOSTAT PFP:21200
A
Removal and Installation EBS00OJ2

CO

MBIB1358E
G

1. Thermostat 2. Rubber ring 3. Water outlet

4. Radiator hose (upper) 5. Heater hose 6. Heater pipe H
7. Copper washer 8. Engine coolant temperature sensor

REMOVAL I
1. Drain engine coolant. Refer to CO-9, "ENGINE COOLANT" .
CAUTION:
Make sure to drain when the engine coolant temperature is cold. J
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pres-
sure coolant escaping from the radiator.
K
2. Remove air duct and air cleaner body. Refer to EM-18, "AIR CLEANER AND AIR DUCT" .
3. Remove radiator hose (upper).
4. Remove water outlet and thermostat. L
● Coolant remaining in the engine is drained. Use tray to collect it.

5. Remove engine coolant temperature sensor if necessary.

6. Remove heater pipe if necessary. M
INSPECTION AFTER REMOVAL
● Place a thread so that it is caught in the valves of the thermostat.
Immerse fully in a container filled with water. Heat while stirring.
(The example in the figure shows the thermostat.)
● 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 temper-
ature and check the valve closing temperature.
● If the measured value is out of the standard value or unusual
valve seating condition is found, replace the thermostat. SLC252B

CO-25
 THERMOSTAT
[CR]
Standard values
Thermostat
Valve opening temperature 86.5 - 89.5°C (188 - 193°F)
Full-open lift amount 8 mm or more/ 101°C (0.31 in/ 214 °F)
Valve closing temperature 83°C (181°F)

INSTALLATION
Install in the reverse order of removal which being careful of the following.
Installation of Thermostat
1. Install the thermostat with the whole circumference of each
flange part fit securely inside the rubber ring.

PBIC0157E

2. Install thermostat with jiggle valve facing the direction shown in

the figure.
NOTE:
Care must be taken not to trap the thermostat jiggle valve.

PBIC1492E

Water Outlet Installation

● Install water pipe with it facing upward.
● Install thermostat in place.

PBIC1493E

Heater Pipe Installation

● Apply liquid gasket to the threads, and install.
Use Genuine Liquid Gasket or equivalent.
INSPECTION AFTER INSTALLATION
● Check for leaks of engine coolant using radiator cap tester adapter (SST: EG17650301) and a radiator
cap tester (commercial service tool) (M/T models without A/C and A/T models) or reservoir tank cap tester
and reservoir tank cap tester adapter (M/T models with A/C). Refer to CO-9, "LEVEL CHECK" .
● Start and warm up engine. Visually check if there is no leaks of engine coolant.

CO-26
 SERVICE DATA AND SPECIFICATIONS (SDS)
[CR]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
A
Standard and Limit EBS00OJL

CAPACITY
Unit: (Imp qt)
CO
Coolant capacity M/T models without A/C and A/T models Approximately 4.9 (4-3/8)
[With reservoir tank (MAX level)] M/T models with A/C Approximately 5.3 (4-5/8)
M/T models without A/C and A/T models 0.7 (5/8) C
Reservoir tank
M/T models with A/C 1.2 (1-1/8)

THERMOSTAT
D
Valve opening temperature 86.5 - 89.5°C (188 - 193°F)
Valve lift 8 mm or more/ 101°C (0.31 in/ 214°F)
Valve closing temperature 83°C (181°F) E

RADIATOR
Unit: kPa (bar, kg/cm2 , psi)
F
Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Radiator cap relief pressure
Limit 59 (0.59, 0.6, 9)
Reservoir tank cap relief pressure 88 (0.88, 0.90, 12.8) G
M/T models without A/C and A/T models 157 (1.57, 1.6, 23)
Leakage test pressure
M/T models with A/C 10 (0.1, 0.10, 1.5)
H
Tightening Torque EBS00OJ4

*1: Parts to be tightened in particular orders

Unit: N·m (kg-m, ft-lb) I
Unit: N·m (kg-m, in-lb)*2
Cooling fan assembly 3.8 - 4.5 (0.39 - 0.45, 34 - 39)*2
Reservoir tank (M/T models without A/C and A/T models) 3.8 - 4.5 (0.39 - 0.45, 34 - 39)*2 J
Cooling fan motor 3.0 - 4.0 (0.31 - 0.40, 27 - 35)*2
Cooling fan (reverse screw) 1.7 - 2.3 (0.18 - 0.23, 15 - 20)*2 K
Water pump 10.0 - 13.7(1.1 - 1.3, 8 - 10)
Water pump pulley 6.9 - 9.5 (0.71 - 0.96, 61 - 84)*2
L
*1 Water suction pipe 16.6 - 23.5 (1.7 - 2.3, 13 - 17)
Water outlet 6.3 - 8.3 (0.65 - 0.84, 56 - 73)*2
Heater pipe 29.0 - 39.0 (3.0 - 4.0, 21 - 29) M
Engine coolant temperature sensor 20 - 27(2.1 - 2.7, 15 - 19)

CO-27
 PRECAUTIONS
[HR]
PRECAUTIONS
[HR] PFP:00001

Precautions For Liquid Gasket EBS01JAY

REMOVAL OF LIQUID GASKET SEALING

● After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
● In areas where the seal cutter is difficult to use, use a plastic
hammer to lightly tap the gasket area.
CAUTION:
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

LIQUID GASKET APPLICATION PROCEDURE

1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
● 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
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
PBIC0003E

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

EMA0622D

● As for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the instruction in this manual.
● Within five minutes of gasket application, install the mating com-
ponent.
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten after the installation.
● 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-28
 PREPARATION
[HR]
PREPARATION PFP:00002
A
Special Service Tools EBS01KBZ

NISSAN Tool number

(RENAULT tool number) Description CO
Tool name

WS39930000 Pressing the tube of liquid gasket

( — ) C
Tube presser

S-NT052

EG17650301 Adapting radiator cap tester to radiator filler E

( — ) neck
Radiator cap tester adapter a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia. F
Unit: mm (in)

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

S-NT224 I
KV99103520 Removing radiator upper and lower tanks
( — )
Radiator plate pliers B J

K
S-NT225

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

M
MLIA0012E

— Adapting tester to reservoir tank

(M.S. 554_01)
Reservoir tank tester adapter

MLIA0013E

— Adapting tester to reservoir tank cap

(M.S. 554_06)
Reservoir tank cap tester adapter

MLIA0014E

CO-29
 PREPARATION
[HR]
Commercial Service Tool EBS01JA8

Tool name Description

Radiator cap tester Checking radiator and radiator cap

PBIC1982E

CO-30
 OVERHEATING CAUSE ANALYSIS
[HR]
OVERHEATING CAUSE ANALYSIS PFP:00012
A
Troubleshooting Chart EBS01JA9

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 —
Physical damage
Clogged radiator cooling Excess foreign material D
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
ate
E
Reduced air flow High resistance to fan rota- Fan assembly —
tion
Damaged fan blades
F
Damaged radiator shroud — — —
Improper engine coolant
Cooling sys- — — —
mixture ratio G
tem parts
malfunction Poor engine coolant quality — Engine coolant viscosity —
Loose clamp
Cooling hose H
Cracked hose
Water pump Poor sealing
Loose
Radiator cap I
Poor sealing
Engine coolant leaks
O-ring for damage, deterio-
Radiator (without A/C mod-
Insufficient engine coolant ration or improper fitting J
els)
Reservoir tank cap (with A/ Cracked radiator tank
C models)
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

CO-31
 OVERHEATING CAUSE ANALYSIS
[HR]
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
Power train 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-32
 COOLING SYSTEM
[HR]
COOLING SYSTEM PFP:21020
A
Cooling Circuit EBS01JAA

CO

PBIC3820E

CO-33
 ENGINE COOLANT
[HR]
ENGINE COOLANT PFP:KQ100

Inspection EBS01JB0

LEVEL CHECK
Without A/C Models
● Check if the reservoir tank engine coolant level is within “MIN” to
“MAX” when engine is cool.
● adjust the engine coolant level as necessary.

SMA412B

With A/C Models

● Check if the reservoir tank coolant level is within MIN to MAX when engine is cool.
● Adjust coolant if too much or too little.
: Vehicle front

MBIB1360E

MBIA0092E

LEAK CHECK
Without A/C Models
● 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/cm 2 , 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-34
 ENGINE COOLANT
[HR]
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant. A
● If anything is found, repair or replace damaged parts.
With A/C Models
CO
● To check for leakage, fit the adapter to the reservoir tank (1),
and then connect it to the tester as shown.

E
MBIB1362E

● Warm up the engine and turn it off.

● Apply pressure to the cooling system and stop pumping. F

Testing pressure : 10 kpa

(0.1 bar, 0.10 kg/cm2 , 1.5 G
psi)
● If the pressure drops, look for leakage.
● Unscrew slowly the adapter from the reservoir tank to reduce H
the pressure in cooling system, and install the reservoir tank
cap.
WARNING: I
MBIA0094E
Never remove the radiator cap when the engine is hot. Seri-
ous 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 EBS01JB1
K
WARNING:
● To avoid being scalded, never change the coolant when the engine is hot.
● 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
Without A/C Models 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-37, "FLUSHING COOLING SYSTEM" .
PBIC1476E

With A/C Models

1. Disconnect radiator lower hose and reservoir tank cap.

CO-35
 ENGINE COOLANT
[HR]
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-37, "FLUSHING COOLING SYSTEM" .

MBIB1360E

REFILLING ENGINE COOLANT

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

MBIB1361E

4. Fill radiator and reservoir tank to specified level.

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

Engine coolant capacity

Without A/C models
With reservoir tank : Approx. 5.6 (4-7/8 Imp qt)
Reservoir tank : 0.7 (5/8 lmp qt)

SMA412B

CO-36
 ENGINE COOLANT
[HR]
With A/C models
A
With reservoir tank : Approx. 6.0 (5-1/4 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.
● For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot.
J
CAUTION:
Be careful not to overheat.
7. Stop the engine. K
8. After cooling engine [approximately 50°C (122 °F) or lower], remove radiator cap and check coolant level.
If the level is low, fill up to the radiator neck again and repeat from step 5.
9. When the coolant level stabilizes, fill reservoir tank up to the “MAX” line. L
10. Check cooling system for leaks with engine running.
11. Allow the engine to cool [approximately 50°C (122°F) or lower].
12. Start the engine. Perform the following cycle three times. Keep an engine speed of 1,000 rpm for approxi- M
mately 30 seconds. Then increase it gradually to 3,000 rpm.
13. During the above step 12, make sure water flow sound is not heard from heater core.
● Sound may be noticeable at heater unit.
14. If water flow sound is heard, repeat from step 4 to 13.
● Clean excess coolant from engine.
FLUSHING COOLING SYSTEM
1. Fill radiator and reservoir tank with water and reinstall radiator 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.
6. Repeat steps 1 through 5 until clear water begins to drain from radiator.

CO-37
 RADIATOR
[HR]
RADIATOR PFP:21400

Removal and Installation EBS01JAD

WITHOUT A/C MODELS

MBIB1366E

Vehicle front 1. Cooling fan assembly 2. Hose clamp

3. Radiator hose (upper) 4. Radiator 5. Radiator cap
6. Mounting rubber (upper) 7. Mounting rubber (lower) 8. Radiator hose (lower)
9. Bracket 10. Reservoir tank cap 11. Reservoir tank
12. Reservoir tank hose
A. To water outlet B. To water suction pipe C. To a of radiator

Refer to GI-9, "Components" for symbol marks in the figure.

CO-38
 RADIATOR
[HR]
WITH A/C MODELS
A

CO

MBIB1367E I

Vehicle front 1. Radiator 2. Mounting rubber (upper)

3. Radiator hose (upper) 4. Hose clamp 5. Reserve tank cap J
6. Hose clamp 7. Reservoir tank hose 8. Reservoir tank
9. Cooling fan assembly 10. Hose clamp 11 Radiator hose (lower)
12. Hose clamp 13 Reservoir tank hose 14. Mounting rubber (lower) K
A. To water outlet B. To water suction pipe

Refer to GI-9, "Contents" for symbol marks in the figure.

L
REMOVAL
Operation Description: Remove radiator core support (lower), and pull out radiator and cooling fan assembly
to the underside of vehicle. M
1. Drain coolant. Refer to CO-9, "ENGINE COOLANT" .
CAUTION:
Make sure to drain when the engine coolant temperature is cold.
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pres-
sure coolant escaping from the radiator.
2. Remove mounting bolts to make relay case movable.
3. Remove the following parts.
● Reservoir tank (with A/C models)

● RH/LH front fender protector

● RH/LH front grille; Refer to EI-11, "FRONT GRILLE" .

● Air Duct; Refer to EM-119, "AIR CLEANER AND AIR DUCT" .

4. Remove radiator hose (upper) and (lower).

5. Fix with ropes so that A/C condenser (1) and RH/LH upper mount units of radiator and cooling fan assem-
bly are placed on radiator core support (upper).

CO-39
 RADIATOR
[HR]
2. Reservoir tank

CAUTION:
Taking parts strength into consideration, lift up at locations
where damage may not occur.

MBIB1363E

Remove radiator core support (lower) with the following proce-

dures.
a. Remove air guide (2) upper clips (1) at radiator right side.
NOTE:
In figure, bumper fascia is omitted for explanation.
b. Remove radiator core support (lower) mounting bolts (RH/LH).
Refer to BL-13, "RADIATOR CORE SUPPORT" .
c. Remove air guide lower clips and remove radiator core support
(lower).
MBIB1364E

6. Loosen ropes, and pull out radiator and cooling fan assembly (1)
to the underside of vehicle, supporting the bottom with suitable
jack.
CAUTION:
Be careful not to damage radiator core and A/C condenser
core.

MBIB1365E

7. Remove reservoir tank (without A/C models).

● Disconnect the reservoir tank from fan shroud to remove.
With force applied in the left direction of vehicle, pull up reser-
voir tank.

PBIC1476E

8. Remove cooling fan assembly from radiator.

CO-40
 RADIATOR
[HR]
INSTALLATION
Install in the reverse order of removal which being careful of the following. A
● When installing radiator core support (lower), make sure upper and lower mount units of radiator and A/C
condenser are fitted in mounting holes of radiator core support (upper/lower).
CO
Disassembly and Assembly of Cooling Fan EBS01JAE

WITHOUT A/C MODELS

C

MBIB1368E

1. Fan shroud 2. Fan motor 3. Fan I

WIHT A/C MODELS

J

MBIB1369E

1. Resistor 2. Fan shroud 3. Fan motor

4. Fan

CO-41
 RADIATOR
[HR]
DISASSEMBLY
1. Remove fan.
CAUTION:
Reverse screw are used for the fan attachment screw.When
removing or attaching, turn the screw the opposite way as
for a normal screw.
2. Remove fan motor from fan shroud.

PBIC1486E

ASSEMBLY
Assemble cooling fan in the reverse order of disassembly.
● Apply thread locking sealant and tighten screw to assemble the fan.
Checking Radiator Cap (Without A/C Models) EBS01JAF

1. Pull the negative-pressure valve to open it and check that it closes completely when released.
● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve.

● Check that there are no unusual conditions in the opening

and closing conditions of the negative-pressure valve.

SMA967B

2. Check radiator cap relief pressure.

Standard:
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2 , 11 - 14 psi)
Limit:
59 kPa (0.59 bar, 0.6 kg/cm2 , 9 psi)
● When connecting the radiator cap to the tester, apply water or
engine coolant to the cap seal part.
● Replace the radiator cap if there is an unusual conditions in
SLC135B

the negative-pressure valve, or if the open-valve pressure is

outside of the standard values.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy resi-
due or foreign material.

CO-42
 RADIATOR
[HR]
Checking Reservoir Tank Cap (With A/C Models) EBS01KBW

A
● Fit the adapter to the tester as shown.
● When connecting the reservoir tank cap to the tester, apply
water or LLC to the cap seal part.
CO
● Check reservoir tank cap relief pressure.

140 kPa (1.4 bar, 1.43 kg/cm2 , 20.3 psi)

C
● Replace the reservoir tank cap if the engine coolant passes
through it, or if any fur signs is detected.
D
MBIB1079E

Checking Radiator EBS01JAG

E
Check radiator for mud or clogging. If necessary, clean radiator as follows.
● Be careful not to bend or damage the radiator fins.
● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, fan shroud
and horns. Then tape the harness and connectors to prevent water from entering. F
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.
G
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.
● Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71 psi) and keep distance more than 30 cm H
(11.8 in).
5. Blow air again into all the radiator core surface once per minute until no water sprays out.
I
Checking Cooling System Hoses EBS01JAH

Check hoses for improper attachment, leaks, cracks, damage, loose connections, chaffing and deterioration.
J

CO-43
 RADIATOR (ALUMINUM TYPE)
[HR]
RADIATOR (ALUMINUM TYPE) PFP:21460

Disassembly and Assembly EBS01JB2

PBIC2075E

1. Upper tank 2. Sealing rubber 3. Core

4. Lower tank

PREPARATION
1. Attach the spacer to the tip of the radiator plate pliers 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 radiator plate pliers A are closed dimen-
sion H′′ is approx. 7.6 mm (0.299 in).
3. Adjust dimension H′′ with the spacer, if necessary.

SLC655C

DISASSEMBLY
1. Remove tank with radiator plate pliers B (SST).

SLC903

CO-44
 RADIATOR (ALUMINUM TYPE)
[HR]
● Grip the crimped edge and bend it upwards so that Tool slips
off. A
CAUTION:
Do not bend excessively.
CO

SLC893

D
● In areas where Tool cannot be used, use a screwdriver to
bend the edge up.
CAUTION: E
Be careful not to damage tank.

G
SLC930

2. Make sure the edge stands straight up. H

SLC931
K
ASSEMBLY
1. Clean contact portion of tank.
L

SLC932

CO-45
 RADIATOR (ALUMINUM TYPE)
[HR]
2. Install sealing rubber.
CAUTION:
Be careful not to twist sealing rubber.
NOTE:
Push it in with fingers.

SLC917A

3. Caulk tank in specified sequence with radiator plate pliers A

(SST).

SLC904

SLC896

● Use pliers in the locations where Tool cannot be used.

SLC897

4. Make sure that the rim is completely crimped down.

Standard height “H” : 8.0 - 8.4 mm (0.315 - 0.331 in)
5. Confirm that there is no leakage.
Refer to CO-34, "LEAK CHECK" .

SLC554A

CO-46
 RADIATOR (ALUMINUM TYPE)
[HR]
INSPECTION
1. Apply pressure with radiator cap tester. A
Specified pressure value
: 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi) CO
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp. C

SLC933
D

2. Check for leakage by soaking radiator in water container.

E

SLC934

CO-47
 WATER PUMP
[HR]
WATER PUMP PFP:21020

Removal and Installation EBS01JAL

PBIC3807E

1. Gasket 2. Water pump 3. Water pump pulley

Refer to GI-9, "Components" for symbol marks in the figure.

REMOVAL
1. Drain engine coolant from radiator. Refer to CO-35, "DRAINING ENGINE COOLANT" .
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pres-
sure coolant escaping from the radiator.
CAUTION:
Perform this step when engine is cold.
2. Steer front wheel to the right.
3. Remove front fender protector (RH). Refer to EI-14, "FENDER PROTECTOR" .
4. Loosen mounting bolts of water pump pulley before loosening belt tension of drive belt.
5. Remove drive belt. Refer to EM-115, "DRIVE BELTS" .
6. Remove water pump pulley.
7. Remove water pump.
● Loosen mounting bolts in reverse order as shown in the fig-
ure.
● Engine coolant will leak from cylinder block, so have a recep-
tacle ready below.
CAUTION:
● Handle water pump vane so that it does not contact any
other parts.
● Water pump cannot be disassembled and should be
replaced as a unit.
KBIA3393J

CO-48
 WATER PUMP
[HR]
INSPECTION AFTER REMOVAL
● Visually check if there is no significant dirt or rusting on water A
pump body and vane (A).
● Make sure that there is no looseness in vane shaft, and that it
turns smoothly when rotated by hand. CO
● Replace water pump, if necessary.

PBIC3808E
D

INSTALLATION
Note the following, and install in the reverse order of removal. E
Water Pump
● Tighten mounting bolts in numerical order as shown in the fig-
ure. F

KBIA3393J
I
Water Pump Pulley
CAUTION:
Do not install mounting bolts (A) to oblong holes (B). J
1 : Water pump pulley

PBIC3809E
M
INSPECTION AFTER INSTALLATION
● Check for engine coolant leaks using radiator cap tester adapter (SST: EG17650301) and radiator cap
tester (commercial service tool) (without A/C models) or reservoir tank cap tester and reservoir tank cap
tester adapter (with A/C models). Refer toCO-34, "LEAK CHECK" .
● Start and warm up engine. Visually check if there is no leaks of engine coolant.

CO-49
 THERMOSTAT
[HR]
THERMOSTAT PFP:21200

Removal and Installation EBS01JAN

PBIC3810E

1. Radiator hose (lower) 2. Water inlet 3. Rubber ring

4. Thermostat
A. To radiator

Refer to GI-9, "Components" for symbol marks in the figure.

REMOVAL
1. Drain engine coolant from radiator. Refer to CO-35, "DRAINING ENGINE COOLANT" .
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pres-
sure coolant escaping from the radiator.
CAUTION:
● Perform this step when engine is cold.

● Do not spill engine coolant on drive belt.

2. Remove reservoir tank. Refer to CO-38, "RADIATOR" .

3. Disconnect radiator hose (lower). Refer to CO-38, "RADIATOR" .
4. Remove water inlet and thermostat.
● Engine coolant will leak from cylinder block, so have a receptacle ready below.

INSPECTION AFTER REMOVAL

● Place a thread (A) so that it is caught in the valves of thermostat
(1). Immerse fully in a container (B) filled with water. Heat while
stirring.
● The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
● Continue heating. Check the full open valve lift amount.
● After checking the maximum valve lift amount, lower the water
temperature and check the valve closing temperature.

PBIC3314J

CO-50
 THERMOSTAT
[HR]
Standard:
Items Thermostat
A
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Maximum valve lift 8 mm/ 95°C (0.315 in/ 203°F)
CO
Valve closing temperature 77°C (171°F)
● If out of the standard, replace thermostat.
C
INSTALLATION
Note the following, and install in the reverse order of removal.
Thermostat D
● Install thermostat with making rubber ring (1) groove fit to ther-
mostat flange (A) with the whole circumference.
E

G
PBIC3811E

● Install thermostat (2) with jiggle valve (A) facing upwards. H

1 : Cylinder block

PBIC3812E K
Water Inlet
After installation, fix water inlet clip (A) on the oil level gauge guide
(1) as shown in the figure. L
B : Positioning

PBIC3755E

INSPECTION AFTER INSTALLATION

● Check for leaks of engine coolant using radiator cap tester adapter (SST: EG17650301) and a radiator
cap tester (commercial service tool) (without A/C models) or reservoir tank cap tester and reservoir cap
tester adapter (with A/C models). Refer to CO-34, "LEAK CHECK" .
● Start and warm up engine. Visually check if there is no leaks of engine coolant.

CO-51
 WATER OUTLET
[HR]
WATER OUTLET PFP:11060

Removal and Installation EBS01JAQ

REMOVAL

PBIC3816E

1. Engine coolant temperature sensor 2. Washer 3. Gasket

4. Radiator hose (upper) 5. Water outlet 6. Heater hose
7. Heater hose 8. Water hose 9. Water hose
A. To electric throttle control actuator B. To heater C. To radiator

Refer to GI-9, "Contents" for symbol marks in the figure.

1. Drain engine coolant from radiator. Refer to CO-35, "DRAINING ENGINE COOLANT" .
WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pres-
sure coolant escaping from the radiator.
CAUTION:
Perform step when engine is cold.
2. Remove air duct (inlet) and air duct. Refer to EM-119, "AIR CLEANER AND AIR DUCT" .
3. Disconnect radiator hose (upper). Refer to CO-38, "RADIATOR" .
4. Disconnect harness connector from engine coolant temperature sensor.
5. Remove water hose and heater hose.
6. Remove water outlet.
7. Remove engine coolant temperature sensor from water outlet, as necessary.
INSTALLATION
Installation is the reverse order of removal.

CO-52
 WATER OUTLET
[HR]
INSPECTION AFTER INSTALLATION
● Check for leaks of engine coolant using radiator cap tester adapter (SST: EG17650301) and a radiator A
cap tester (commercial service tool) (without A/C models) or reservoir tank cap tester and reservoir tank
cap tester adapter (with A/C models). Refer to CO-34, "LEAK CHECK" .
● Start and warm up engine. Visually check if there is no leaks of engine coolant. CO

CO-53
 SERVICE DATA AND SPECIFICATIONS (SDS)
[HR]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Standard and Limit EBS01JAR

CAPACITY
Unit: (Imp qt)

Coolant capacity Without A/C models Approximately 5.6 (4-7/8)

[With reservoir tank (MAX level)] With A/C models Approximately 6.0 (5-1/4)
Without A/C models 0.7 (5/8)
Reservoir tank
With A/C models 1.2 (1-1/8)

THERMOSTAT
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Maximum valve lift 8 mm/ 95°C (0.315 in/ 203°F)
Valve closing temperature More than 77°C (171°F)

RADIATOR
Unit: kPa (bar, kg/cm2 , psi)
Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Radiator cap relief pressure
Limit 59 (0.59, 0.6, 9)
Reservoir tank cap relief pressure 140 (1.4, 1.43, 20.3)
Without A/C models 157 (1.57, 1.6, 23)
Leakage test pressure
With A/C models 10 (0.1, 0.10, 1.5)

CO-54
 APPLICATION NOTICE
[K9K]
APPLICATION NOTICE
[K9K] PFP:00000
A
How to Check Vehicle Type EBS01IO2

Confirm K9K engine type with Model written on identification plate (refer to GI-44, "IDENTIFICATION INFOR-
MATION" ),then refer to service information in CO section. CO
Vehicle type Engine type
xTKxxxxK12Vxx Euro3 48kW
xTKxxxxK12Yxx Euro3 60kW
C

xTKxxxxK12Txx Euro4 50kW

xTKxxxxK12Uxx Euro4 63kW D

CO-55
 PRECAUTIONS
[K9K]
PRECAUTIONS PFP:00001

Precautions For Liquid Gasket EBS01C7N

REMOVAL OF LIQUID GASKET

● After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
● In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the gasket applied area.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating
surfaces.
PBIC0275E

LIQUID GASKET APPLICATION PROCEDURE

1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
PBIC0003E

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

EMA0622D

● As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes.
Make sure to read the instruction in this manual.
● Within five minutes of gasket application, install the mating
component.
● If the liquid gasket protrudes, wipe it off immediately.

● Do not retighten after the installation.

● After 30 minutes or more have passed from the installation, fill

the engine oil and coolant.
CAUTION: SEM159F
If there are instructions in this manual, observe them.

CO-56
 PREPARATION
[K9K]
PREPARATION PFP:00002
A
Special Service Tools EBS01C7O

NISSAN tool number

(RENAULT too number) Description CO
Tool name

WS39930000 Pressing the tube of liquid gasket

( — ) C
Tube pressure

S-NT052

KV99103510 Installing radiator upper and lower tanks E

( — )
Radiator plate pliers A

S-NT224
G
KV99103520 Removing radiator upper and lower tanks
( — )
Radiator plate pliers B
H

S-NT225 I
— Leak checking
(M.S. 554_07) Checking reservoir tank cap
Tester J

K
MLIA0012E

— Adapting tester to reservoir tank

(M.S. 554_01) L
Reservoir tank cap tester adapter A

M
MLIA0013E

— Adapting tester to reservoir tank cap

(M.S. 554_06)
Reservoir tank cap tester adapter B

MLIA0014E

CO-57
 OVERHEATING CAUSE ANALYSIS
[K9K]
OVERHEATING CAUSE ANALYSIS PFP:00012

Troubleshooting Chart EBS01C7P

Symptom Check items

Water pump malfunction Worn timing belt
Thermostat stuck closed —
Dust contamination or
Poor heat transfer Damaged fins paper clogging —
Mechanical damage
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
ate
Reduced air flow High resistance to fan rota- Fan assembly —
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper coolant mixture
Cooling sys- — — —
ratio
tem parts
malfunction Poor coolant quality — — —
Loose clamp
Cooling hose
Cracked hose
Water pump Poor sealing
Loose
Reservoir tank 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
Overflowing reservoir tank Cylinder head gasket dete-
cooling system
rioration

CO-58
 OVERHEATING CAUSE ANALYSIS
[K9K]
Symptom Check items
A
High engine rpm under no
load
Driving in low gear for
Abusive driving CO
extended time
Driving at extremely high
speed
— Overload on engine C
Powertrain system mal-
function
Installed improper size
Except cool- —
wheels and tires D
ing system
parts mal- Dragging brakes
function
Improper ignition timing
E
Blocked bumper —
Installed car brassiere
Blocked radiator grille Mud contamination or F
Blocked or restricted air paper clogging —
flow
Blocked radiator —
Blocked condenser G
—
Installed large fog lamp

CO-59
 COOLING SYSTEM
[K9K]
COOLING SYSTEM PFP:21020

Cooling Circuit EBS01FHO

MBIB1410E

1. Engine 2. Radiator 3. Heater core

4. Reservoir tank 5. Water pump 6. Thermostat
7. Air relief plug 8. Oil cooler 9. EGR cooler

CO-60
 ENGINE COOLANT
[K9K]
ENGINE COOLANT PFP:KQ100
A
Inspection EBS01C7Q

LEVEL CHECK
● Check if the reservoir tank coolant level is within MIN to MAX when engine is cool. CO
● Adjust coolant if too much or too little.

E
MBIA0092E

MBIA0093E I

LEAK CHECK
J
● To check for leakage, fit the adapter to the reservoir tank, and
then connect it to the tester as shown.
● Warm up the engine and turn it off.
K
● Apply pressure to the cooling system and stop pumping at 10
kPa (0.1 bar, 0.10 kg/cm2 , 1.5psi) .
● If the pressure drops, look for leakage. L
● Unscrew slowly the adapter from the reservoir tank to reduce
the pressure in cooling system, and install the reservoir tank
cap. M
WARNING: MBIA0094E

Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure engine coolant escaping from the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.

CO-61
 ENGINE COOLANT
[K9K]
Changing Engine Coolant EBS01C7R

WARNING:
● To avoid being scalded, never change the coolant when the engine is hot.
● Wrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn
to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT
1. Remove engine undercover.
2. Disconnect lower radiator hose, and remove reservoir tank cap
and air relief plug.
3. Remove reservoir tank, drain coolant, then clean reservoir tank.
4. Check drained coolant for contaminants such as rust, corrosion
or discoloration.
If contaminated, flush engine cooling system. Refer to CO-63,
"FLUSHING COOLING SYSTEM" .
5. Remove air relief plug from water outlet.
Refer to CO-72, "WATER OUTLET" .
MBIB1056E

REFILLING ENGINE COOLANT

● Before start working, turn off the automatic air conditioner and the blower motor.
1. Install reservoir tank, lower radiator hose and air relief plug.
2. Fill reservoir tank slowly with coolant until coolant spills from the air relief hole. Refer to CO-72, "WATER
OUTLET" .
● Put a cloth under the air relief plug to prevent engine coolant to dampen the crankshaft position
sensor.
● Fill coolant to the MAX level line of the reservoir tank at a rate
of 2 litre (1-3/4 lmp qt)/min or lower.

SMA412B

3. Close the air relief plug.

CAUTION:
If the filling rate is too fast, this could lead to air being mixed in the coolant. Be sure to fill the cool-
ant slowly according to the rate indicated above.
Use genuine Nissan anti-freeze coolant or equivalent mixed with water (distilled or demineralised).
Refer to MA-35, "RECOMMENDED FLUIDS AND LUBRICANTS" .
Engine coolant capacity (With reservoir tank)
Without intercooler: 6.5 litre (5-3/4 lmp qt)
With intercooler: 7.0 litre (6-1/8 lmp qt)

Reservoir tank capacity 1.2 litre (1-1/8 lmp qt)

4. Warm up the engine for approximately five minutes without reservoir tank cap installed, and then turn off
the engine and loose air relief plug until coolant spills from air relief hole.
● If coolant overflows reservoir tank hole, install filler cap.

● Watch engine coolant temperature warning light so as not overheat the engine during all of the
operation.

CO-62
 ENGINE COOLANT
[K9K]
WARNING:
● Be careful not be scaled with hot engine coolant or vacuum pump when operating. A
● Radiator fan blade can start at any time and make personal injuries.

5. Close the air relief plug and run the engine at 2,000 rpm until the upper hose comes hot and radiator fan
operates. Let the engine running approximately 5 minutes at idle speed and check for sound of coolant CO
flow while running engine from idle up to 3,000 rpm.
● Sound may be noticeable at heater water cock.

6. If sound is heard, bleed air from cooling system by repeating steps 4 through 5 until coolant lever no C
longer drops.
● Check the radiator lower hose for any signs of leakage.

7. Turn off the engine and let it cool down. D

● Cool down using a fan to reduce the time.

8. After cooling period, loose the air relief plug and check if coolant spills from the air relief hole. In other
case, remove the air relief plug until the coolant spills, and then close the relief air plug. Bleed air from E
cooling system by repeating steps 5 through 8 until the coolant spills immediately.
9. Check the engine coolant level when engine is cool and refill to MAX level line if the level is lower.
● Clean excess coolant from engine. F

FLUSHING COOLING SYSTEM

1. Fill reservoir tank with water until water spills from the air relief hole, then close air relief plug. Reinstall
G
reservoir tank cap.
2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load. H
4. Stop engine and wait until it cools down.
5. Drain water.
6. Repeat steps 1 through 5 until clear water begins to drain from radiator. I
7. Blow compressed air into cooling circuit through the reservoir tank valve hole to drain all the water.

CO-63
 RADIATOR
[K9K]
RADIATOR PFP:21400

Removal and Installation EBS01C7S

Euro3 48kW models with A/C and Euro3 60kW engine models

MBIB1315E

1. Radiator 2. Mounting rubber 3. Radiator hose (upper)

4. Hose clamp 5. Hose clamp 6. Reservoir tank hose
7. Reservoir tank 8. Cooling fan assembly 9. Hose clamp
10. Radiator hose (lower) 11. Hose clamp 12. Reservoir tank hose
13. Mounting rubber

CO-64
 RADIATOR
[K9K]
Euro3 48kW engine models without A/C
A

CO

MBIB1316E I
1. Radiator 2. Mounting rubber 3. Radiator hose (upper)
4. Hose clamp 5. Hose clamp 6. Reservoir tank hose
7. Reservoir tank 8. Cooling fan assembly 9. Hose clamp J
10. Radiator hose (lower) 11. Hose clamp 12. Reservoir tank hose
13. Mounting rubber
K
WARNING:
Never remove the reservoir tank 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 quar-
ter turn to allow built-up pressure to escape. Carefully remove the cap by turning it all the way. L

REMOVAL
1. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" .
M
2. Remove air cleaner case and air duct (inlet). Refer to EM-247, "AIR CLEANER AND AIR DUCT" .
3. Remove reservoir tank hose bracket bolt from radiator upper mounting bracket (RH side).
4. Remove radiator fan motor harnesses.
5. Remove engine undercover.
6. Drain engine coolant. Refer to CO-62, "DRAINING ENGINE COOLANT" .
CAUTION:
Perform when engine is cold.
7. Disconnect radiator upper hose, reservoir tank hose and mounting bracket.
8. Remove radiator and radiator fan assembly.
● For model with A/C, remove radiator and condenser assembly. Refer to ATC-92, "REFRIGERANT LINES"
.
● For model with charge air cooler. Refer to EM-250, "CHARGE AIR COOLER" .
CAUTION:
● Do not damage or scratch radiator core when removing.

CO-65
 RADIATOR
[K9K]
INSTALLATION
● Reinstall any parts removed in reverse order of removal.
● Check for engine coolant leaks. Refer to CO-61, "LEAK CHECK" .
Disassembly and Assembly Radiator Fan EBS01C7T

Euro3 48kW models with A/C and Euro3 60kW engine models

MBIB1317E

1. Radiator fan motors 2. Radiator fan shroud 3. Radiator fan

4. Retaining nut

CO-66
 RADIATOR
[K9K]
Euro3 48kW engine models without A/C
A

CO

MBIB1318E I
1. Radiator fan motors 2. Radiator fan shroud 3. Radiator fan
4. Clip
J
DISASSEMBLY
1. Remove radiator fan and shroud assembly.
2. Remove radiator fan as shown.
K

MBIB1062E

MBIB1063E

3. Remove fan motor from fan shroud.

CO-67
 RADIATOR
[K9K]

ASSEMBLY
Install in the reverse order of removal.
Checking Reservoir Tank Cap EBS01C7U

● Fit the adapter to the tester as shown.

● When connecting the reservoir tank cap to the tester, apply
water or LLC to the cap seal part.
● Check reservoir tank cap relief pressure.

130 - 150 kPa (1.3 - 1.5 bar, 1.33 - 1.53 kg/cm2 , 18.9 -
21.8 psi)
● Replace the reservoir tank cap if the engine coolant passes
through it, or if any fur signs is detected.
MBIB1079E

Checking Radiator EBS01C7V

Check radiator for mud or clogging. If necessary, clean radiator as follows.

● Be careful not to bend or damage the radiator fins.
● When radiator is cleaned without removal, remove all surrounding parts such as radiator 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.
● Use compressed air lower than 490 kPa (4.9 bar 5 kg/cm2 , 71psi) and keep distance more than 30 cm
(11.8 in).
5. Blow air again into all the radiator core surface once per minute until no water sprays out.

CO-68
 WATER PUMP
[K9K]
WATER PUMP PFP:21020
A
Removal and Installation EBS01C7W

CO

MBIB1232E
G

1. Water pump 2. Gasket 3. Cylinder block

WARNING: H
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
REMOVAL I
1. Remove the following parts.
● Battery ground cable
J
● Undercover

● RH front wheel

2. Remove right side splash cover. K

3. Remove drive belt. Refer to EM-244, "DRIVE BELTS" .
4. Drain engine coolant. Refer to CO-62, "DRAINING ENGINE COOLANT" .
CAUTION: L
Perform when engine is cold.
5. Remove timing belt and inner cover. Refer to EM-273, "TIMING BELT" .
6. Remove the water pump. M
● Coolant will leak from the 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.

INSPECTION AFTER REMOVAL

● Visually make sure there is no significant dirt or rusting on the
water pump body and vane.
● Make sure there is no looseness in the vane shaft, and that it
turns smoothly when rotated by hand.
● If there are any unusualness, replace the water pump assembly.

MBIB0546E

CO-69
 WATER PUMP
[K9K]
INSTALLATION
● Install in the reverse order of removal.
INSPECTION AFTER INSTALLATION
● Check for engine coolant leaks using reservoir tank cap tester. Refer to CO-61, "LEAK CHECK" .

CO-70
 THERMOSTAT
[K9K]
THERMOSTAT PFP:21200
A
Inspection EBS01FHN

● Place a thread so that it is caught in the valves of the thermostat.

Immerse fully in a container filled with water. Heat while stirring. CO
(The example in the figure shows the thermostat.)
● The valve opening temperature is the temperature at which the
valve opens and falls from the thread. C
● Continue heating. Check the full-open lift amount.
● After checking the full-open lift amount, lower the water temper-
ature and check the valve closing temperature. D
● If the measured value is out of the standard value or unusual
valve seating condition is found, replace the thermostat. SLC252B

Temperature °C (°F)
Start of opening 89 (192) F
End of opening 97 - 101 (207 - 214)

CO-71
 WATER OUTLET
[K9K]
WATER OUTLET PFP:11060

Removal and Installation EBS01C7X

MBIA0090E

1. Clip 2. Gasket 3. Radiator upper hose

4. Water outlet 5. O-ring 6. Water temperature sensor
7. Heater hose 8. Air relief plug

REMOVAL
1. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" .
2. Remove air cleaner case and air duct (inlet). Refer to EM-247, "AIR CLEANER AND AIR DUCT" .
3. Remove rear engine slinger. Refer to EM-280, "ENGINE ASSEMBLY" .
4. Remove vacuum hose.
5. Remove vacuum pump. Refer to EM-269, "VACUUM PUMP" .
6. Drain engine coolant. Refer to CO-62, "DRAINING ENGINE COOLANT" .
CAUTION:
Perform when engine is cold.
7. Remove radiator upper hose. Refer to CO-64, "RADIATOR" .
8. Remove heater hose.
9. Disconnect reservoir tank hose. Refer to CO-64, "RADIATOR" .
10. Remove water outlet.
INSTALLATION
Install in the reverse order of removal.

CO-72