ENGINESECTION ENGINE COOLING SYSTEM CO A CO C D CONTENTS FUNCTION DIAGNOSIS ........................... .... 2 DESCRIPTION ............................................... ..... 2 Engine Cooling System ..................................... ...... 2 Engine Cooling System Schematic ................... ...... 2 E ON-VEHICLE REPAIR .............................. ... 13 RADIATOR ........................................................ 13 Exploded View ..................................................... ....13 Removal and Installation ..................................... ....13 Inspection ............................................................ ....15 F G SYMPTOM DIAGNOSIS ........................... .... 3 OVERHEATING CAUSE ANALYSIS ............. ..... 3 Troubleshooting Chart ........................................ ...... 3 COOLING FAN .................................................. 16 Exploded View ..................................................... ....16 Removal and Installation ..................................... ....16 Disassembly and Assembly ................................. ....17 Inspection ............................................................ ....17 H PRECAUTION ........................................... .... 5 PRECAUTIONS .............................................. ..... 5 Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ............................................................. ...... 5 Liquid Gasket ..................................................... ...... 5 I WATER PUMP .................................................. 18 Exploded View ..................................................... ....18 Removal and Installation ..................................... ....18 Inspection ............................................................ ....21 J PREPARATION ........................................ .... 7 PREPARATION .............................................. ..... 7 Special Service Tool ........................................... ...... 7 Commercial Service Tools ................................. ...... 7 WATER INLET AND THERMOSTAT ASSEMBLY .................................................................... 23 Exploded View ..................................................... ....23 Removal and Installation ..................................... ....23 Inspection ............................................................ ....24 K L ON-VEHICLE MAINTENANCE ................. .... 8 ENGINE COOLANT ....................................... ..... 8 Inspection ............................................................ ...... 8 Draining ............................................................... ...... 8 Refilling ............................................................... ...... 9 Flushing ............................................................... .... 10 WATER OUTLET AND WATER PIPING .......... 25 Exploded View ..................................................... ....25 Removal and Installation ..................................... ....25 Inspection ............................................................ ....26 M N SERVICE DATA AND SPECIFICATIONS (SDS) ......................................................... ... 27 SERVICE DATA AND SPECIFICATIONS (SDS) ................................................................. 27 Periodical Maintenance Specification .................. ....27 Radiator ............................................................... ....27 Thermostat .......................................................... ....27 O RADIATOR ..................................................... ....12 RADIATOR CAP .................................................... .... 12 RADIATOR CAP : Inspection .............................. .... 12 RADIATOR ............................................................ .... 12 RADIATOR : Inspection ...................................... .... 12 P CO-1 DESCRIPTION < FUNCTION DIAGNOSIS > FUNCTION DIAGNOSIS DESCRIPTION Engine Cooling System INFOID:0000000003793159 JPBIA1682GB Engine Cooling System Schematic INFOID:0000000003793160 JPBIA1683GB CO-2 dirt.OVERHEATING CAUSE ANALYSIS < SYMPTOM DIAGNOSIS > SYMPTOM DIAGNOSIS OVERHEATING CAUSE ANALYSIS Troubleshooting Chart Symptom Water pump malfunction Thermostat stuck closed Poor heat transfer Damaged fins Clogged radiator cooling tube Cooling fan does not operate Reduced air flow High resistance to fan rotation Damaged fan blades Damaged radiator shroud Cooling system parts malfunction Improper engine coolant mixture ratio Poor engine coolant quality — — — — — Engine coolant density Cooling hose Water pump Radiator cap Engine coolant leakage Insufficient engine coolant Radiator Loose clamp Cracked hose Poor sealing Loose Poor sealing O-ring for damage. sand. etc.) INFOID:0000000003793161 A CO C D — E F G H I J K L M N O P CO-3 . deterioration or improper fitting Cracked radiator tank Cracked radiator core Reservoir tank Overflowing reservoir tank Exhaust gas leakage into cooling system Cracked reservoir tank Cylinder head deterioration Cylinder head gasket deterioration — — — Fan assembly — Check items Worn or loose drive belt — Dust contamination or paper clogging Physical damage Excess foreign material (rust. OVERHEATING CAUSE ANALYSIS < SYMPTOM DIAGNOSIS > Symptom Check items High engine rpm under no load Abusive driving Driving in low gear for extended time Driving at extremely high speed — Overload on engine Powertrain system malfunction Installed improper size wheels and tires Dragging brakes Improper ignition timing Blocked bumper Blocked radiator grille Blocked or restricted air flow Blocked radiator Blocked condenser Installed large fog lamp — Installed car brassiere Mud contamination or paper clogging — Blocked air flow — — Except cooling system parts malfunction CO-4 . WARNING: • To avoid rendering the SRS inoperative. all maintenance must be performed by an authorized NISSAN/INFINITI dealer. C D E F G Liquid Gasket REMOVAL OF LIQUID GASKET SEALING • After removing mounting nuts and bolts. For removal of Spiral Cable and Air Bag Module. Using a scraper (A). CAUTION: If for some unavoidable reason tool such as a screwdriver is used. use a plastic hammer to lightly tap the parts. mounting bolts. see the “SRS AIRBAG”. and then slide (C) it by tapping on the side as shown in the figure. and may only deploy one front air bag. including incorrect removal and installation of the SRS. used along with a front seat belt. depending on the severity of a collision and whether the front occupants are belted or unbelted. remove old liquid gasket adhering to the liquid gasket application surface and the mating surface. INFOID:0000000003793163 H I J K JPBIA0052ZZ L LIQUID GASKET APPLICATION PROCEDURE 1. helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. can lead to personal injury caused by unintentional activation of the system. • In areas where seal cutter [SST: KV10111100 (J37228)] is difficult to use. • Remove liquid gasket completely from the groove of the liquid gasket application surface. • Improper maintenance. M N 2. grease and foreign materials. and bolt holes. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Information necessary to service the system safely is included in the “SRS AIRBAG” and “SEAT BELT” of this Service Manual. This system includes seat belt switch inputs and dual stage front air bag modules.PRECAUTIONS < PRECAUTION > PRECAUTION PRECAUTIONS Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" A CO INFOID:0000000003801896 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”. to remove it. The SRS system uses the seat belt switches to determine the front air bag deployment. • Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation. O P JPBIA0053ZZ CO-5 . • Tap (B) the seal cutter [SST: KV10111100 (J37228)] to insert it. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture. separate the mating surface using the seal cutter [SST: KV10111100 (J37228)] (A) and remove old liquid gasket sealing. be careful not to damage the mating surfaces. CAUTION: Be careful not to damage the mating surfaces. • If there is a groove for the liquid gasket application. Attach liquid gasket tube to the tube presser (commercial service tool). apply liquid gasket to the groove. wipe it off immediately. • If liquid gasket protrudes. it should be applied outside the holes. A : Groove : Inside • Within five minutes of liquid gasket application. Use Genuine Liquid Gasket or equivalent. observe them. JPBIA0010ZZ CO-6 . • Never retighten after mounting bolts and nuts the installation. Check to read the text of service manual. 4.PRECAUTIONS < PRECAUTION > 3. Occasionally. Apply liquid gasket without breaks to the specified location with the specified dimensions. CAUTION: If there are specific instructions in this manual. install the mating component. EMA0622D • As for the bolt holes (B). fill engine oil and engine coolant. • After 30 minutes or more have passed from the installation. normally apply liquid gasket inside the holes. 626) dia. Unit: mm (in) O P S-NT564 CO-7 .) Tool name KV10111100 (J37228) Seal cutter INFOID:0000000003793164 A CO Description Removing water pump cover C D E NT046 Commercial Service Tools Tool name Tube presser Description F INFOID:0000000003793165 G Pressing the tube of liquid gasket H I S-NT052 Power tool Loosening nuts and bolts J K PBIC0190E L Checking radiator and radiator cap Radiator cap tester M N PBIC1982E Radiator cap tester adapter Adapting radiator cap tester to radiator cap and radiator pipe (upper) filler neck a: 28 (1.10) dia.PREPARATION < PREPARATION > PREPARATION PREPARATION Special Service Tool Tool number (SPX North America No.236) dia. b: 31.4 (1.3 (1. c: 41. 2. A B : MAX : MIN INFOID:0000000003793166 • Adjust the engine coolant level as necessary. Refer to EM-110. : Vehicle front JPBIA2225ZZ 3. CAUTION: Higher test pressure than specified may cause radiator damage. WARNING: Never remove radiator cap when engine is hot. • If anything is found. First. • Wrap a thick cloth around radiator cap and carefully remove radiator cap. Remove reservoir tank as necessary. turn radiator cap a quarter of a turn to release built-up pressure. NOTE: In a case that engine coolant decreases. JPBIA0102ZZ LEAKAGE • To check for leakage. Serious burns could occur from high-pressure engine coolant escaping from radiator. CO-8 . and drain engine coolant and clean reservoir tank before installing. Then turn radiator cap all the way. open water drain plugs on cylinder block. PBIC5121J Draining INFOID:0000000003793167 WARNING: • To avoid being scalded. When draining all of engine coolant in the system. and then remove radiator cap. never change engine coolant when the engine is hot. repair or replace damaged parts. "Disassembly and Assembly". Testing pressure : Refer to CO-27.ENGINE COOLANT < ON-VEHICLE MAINTENANCE > ON-VEHICLE MAINTENANCE ENGINE COOLANT Inspection LEVEL • Check if the reservoir tank engine coolant level is within the “MIN” to “MAX” when the engine is cool. Remove engine under cover. Open radiator drain plug (1) at the bottom of radiator. "Radiator". replenish radiator with engine coolant. apply pressure to the cooling system with the radiator cap tester (commercial service tool) (A) and radiator cap tester adapter (commercial service tool) (B). 1. Refer to CO-10. "Periodical Maintenance Specification". CO C 2. and continue filling the engine coolant. :Refer to CO-27. corrosion or discoloration. and reservoir tank if removed. Refer to EM-26. CAUTION: Never adhere the engine coolant to electronic equipments. (alternator etc. F G H JPBIA2226ZZ 5. If water drain plugs on cylinder block are removed. connect heater hose.ENGINE COOLANT < ON-VEHICLE MAINTENANCE > 4. CAUTION: Be sure to clean drain plug and install with new O-ring. "Fluids and Lubricants". • Use Genuine NISSAN Engine Coolant or equivalent in its quality mixed with water (distilled or demineralized). Check drained engine coolant for contaminants such as rust. 3. If contaminated. Check that each hose clamp has been firmly tightened. "Flushing". Remove air duct assembly and air cleaner cases (upper and lower) assembly. and radiator drain plug. to specified level. "Disassembly and Assembly". Tightening torque : Refer to CO-13. M N O P JPBIA0102ZZ CO-9 . • When engine coolant overflows disconnected heater hose. "Exploded View". flush the engine cooling system. Engine coolant capacity (With reservoir tank at “MAX” level) Reservoir tank engine coolant capacity (At “MAX” level) A B : MAX : MIN I J K L JPBIA0412ZZ : Refer to CO-27. close and tighten them. "Exploded View". Refer to MA-11. Refer to EM-110. 4. Disconnect heater hose (1) at the position ( : Vehicle front D E ) in the figure. Install reservoir tank if removed. Fill radiator. "Periodical Maintenance Specification". A INFOID:0000000003793168 Refilling 1.) • Pour engine coolant through engine coolant filler neck slowly of less than 2 (1-3/4 lmp qt) a minute to allow air in system to escape. and radiator drain plug. Disconnect heater hose (1) at the position ( : Vehicle front ) in the figure. and steps from 7 to 14 until engine coolant level no longer drops. "Exploded View". Refer to CO-8. connect heater hose. • Sound may be noticeable at heater unit. JPBIA2226ZZ 4. Fill radiator and reservoir tank with water and reinstall radiator cap. Install reservoir tank if removed. Install air duct assembly and air cleaner cases (upper and lower) assembly. Repeat steps 7 through 10 two or more times with radiator cap installed until engine coolant level no longer drops.) • When water overflows disconnected heater hose. CAUTION: Never adhere the engine coolant to electronic equipments. bleed air from cooling system by repeating step 5. refill radiator up to filler neck with engine coolant. CAUTION: Watch water temperature gauge so as not to overheat engine.) 10. Tightening torque : Refer to CO-13. If sound is heard. If water drain plugs on cylinder block are removed. INFOID:0000000003793169 2. Refer to EM-26. Rev the engine two or three times under no-load. Stop the engine and cool down to less than approximately 50°C (122°F). 6. 3. Install radiator cap. "Exploded View". 8. Refill reservoir tank to “MAX” level line with engine coolant. • Cool down using fan to reduce the time. and check for sound of engine coolant flow while running engine from idle up to 3. 8.ENGINE COOLANT < ON-VEHICLE MAINTENANCE > 6. and continue filling the water. • If necessary. "Exploded View". close and tighten them. 11. 9. "Draining". (alternator etc. 14. Warm up engine until opening thermostat. Flushing 1. 7.000 rpm with heater temperature controller set at several position between “COOL” and “WARM”. Check cooling system for leakage with engine running. Repeat step 13 three times. Refer to EM-110. 15. Run the engine and warm it up to normal operating temperature. 12. Warm up the engine.000 rpm. Standard for warming-up time is approximately 10 minutes at 3. Remove air duct assembly and air cleaner cases (upper and lower) assembly. Refer to EM-26. CAUTION: Never adhere the water to electronic equipments. (alternator etc. CAUTION: Be sure to clean drain plug and install with new O-ring. 5. CO-10 . "Disassembly and Assembly". Stop the engine and wait until it cools down. 13. 7. Drain water from the system. • Check thermostat opening condition by touching radiator hose (lower) to see a flow of warm water. ENGINE COOLANT < ON-VEHICLE MAINTENANCE > 9. Repeat steps 1 through 8 until clear water begins to drain from radiator. A CO C D E F G H I J K L M N O P CO-11 . Apply water again to all radiator core surfaces once per minute. "Radiator". . . 5. remove all surrounding parts such as radiator cooling fan assembly and horns. Apply water by hose to the back side of the radiator core vertically downward.RADIATOR < ON-VEHICLE MAINTENANCE > RADIATOR RADIATOR CAP RADIATOR CAP : Inspection • Check valve seat (A) of radiator cap. Blow air again into all the radiator core surfaces once per minute until no water sprays out. Stop washing if any stains no longer flow out from radiator. clean radiator as follows: CAUTION: • Be careful not to bend or damage radiator fins. 5 kg/cm2. CAUTION: When installing radiator cap.When connecting radiator cap to the radiator cap tester (commercial service tool) and the radiator cap tester adapter (commercial service tool) (A).81 in).Check that there are no unusualness in the opening and closing conditions of negative-pressure valve. If necessary. • Use compressed air lower than 490 kPa (4. JPBIA1961ZZ INFOID:0000000003793170 • Check radiator cap relief pressure. CO-12 . RADIATOR RADIATOR : Inspection INFOID:0000000003793171 Check radiator for mud or clogging. 4. . thoroughly wipe out the radiator pipe (upper) filler neck to remove any waxy residue or foreign material. . Standard and limit : Refer to CO-27.Check if valve seat has no soil and damage.Check that there is no dirt or damage on the valve seat of radiator cap negative-pressure valve. . 71 psi) and keep distance more than 30 cm (11.9 bar. apply engine coolant to the cap seal surface. 2.Check if valve seat is swollen to the extent that the edge of the plunger (B) cannot be seen when watching it vertically from the top. Then tape harness and connectors to prevent water from entering. 3. Blow air into the back side of radiator core vertically downward. JPBIA0109ZZ • Replace radiator cap if there is an unusualness related to the above three. • When radiator is cleaned without removal. 1. Water drain hose 16. To water outlet 11. Mounting rubber (lower) 20. Clamp Radiator cap adapter Radiator hose (upper) N 10. Removal and Installation REMOVAL INFOID:0000000003793173 CO-13 . Mounting rubber (upper) 17. 4. To transaxle assembly 12. Cooling fan assembly C. Radiator hose (lower) A. 8. To water inlet O P Refer to GI-4. Grommet B. Radiator hose (lower) 22. 9. Clamp 23. Reservoir tank Radiator cap Clamp 3. 5. O-ring 14.RADIATOR < ON-VEHICLE REPAIR > ON-VEHICLE REPAIR RADIATOR Exploded View INFOID:0000000003793172 A CO C D E F G H I J K L JPBIA2200GB M 1. Radiator hose (upper) 13. Radiator upper clip 18. CVT fluid cooler hose 24. Drain plug 15. 6. Reservoir tank cap Reservoir tank hose Radiator pipe (upper) 2. "Components" for symbols in the figure. 7. Radiator pipe (lower) 21. CVT fluid cooler hose 25. Radiator 19. Drain engine coolant from radiator. Disconnect radiator hose (lower) from radiator. 4. 2. and then move it to aside. CAUTION: Be careful not to damage or scratch on radiator core. and installation is the reverse order of removal. 3. Disconnect Low-pressure flexible hose from lower pressure pipe. Remove radiator cap adapter and radiator hoses (upper) and radiator pipe (upper) assembly. CAUTION: • Perform this step when the engine is cold. Carefully remove radiator cap by turning it all the way. 7. CAUTION: Be careful not to damage condenser core. • Hood lock: Refer to DLK-220. Refer to CO-8. • Never spill engine coolant on drive belt. 6. Remove radiator upper clip (2) by pulling the tabs (A) outside to release the lock (B) and then remove mounting rubbers (upper) (1). 9. Slowly turn it a quarter of a turn to release built-up pressure. Wrap a thick cloth around the cap. "Exploded View". "Exploded View". Disconnect reservoir tank hose from radiator pipe (upper). use the following method to check it is fully connected. CAUTION: Be careful not to allow engine coolant to contact drive belt. "Exploded View". Remove condenser. then insert radiator upper clip straight into radiator core connections until a click is heard. 3. • Visually confirm that two radiator upper clips are connected to JPBIA1690ZZ radiator core connections. "Exploded View". "Draining". • Horn: Refer to HRN-6. 5. Refer to HA-46. • Install blind plug to avoid leakage of CVT fluid. • Air duct (inlet): Refer to EM-26. Install mounting rubbers (upper) (1) on mounting pins (A) of radiator. Refer to HA38. Remove the following parts: • Engine under cover. CO-14 . After connecting radiator upper clip. 1. Disconnect CVT fluid cooler hoses from radiator. Serious burns could occur from high-pressure engine coolant escaping from radiator. Align radiator upper clip (2) with radiator core connection (B). JPBIA1689ZZ 10. • Move radiator upper clip and the radiator forward and backward to check they are securely connected. C : Mounting pin : Vehicle front CAUTION: Never pull the tabs outside excessively to prevent it from damping. Lift up and remove radiator from front of radiator core support.RADIATOR < ON-VEHICLE REPAIR > WARNING: Never remove radiator cap when engine is hot. : Vehicle front 2. INSTALLATION Note the following. "Exploded View". Radiator Upper Clip Install radiator upper clip on radiator core connection as follows: 1. 8. • Start and warm up the engine.RADIATOR < ON-VEHICLE REPAIR > Inspection INSPECTION AFTER INSTALLATION INFOID:0000000003793174 A • Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the CO radiator cap tester (commercial service tool). C D E F G H I J K L M N O P CO-15 . Visually check that there is no leakage of engine coolant and CVT fluid. Refer to CO-8. "Inspection". and move battery tray bracket to aside. Refer to SR-18. Remove battery tray bracket mounting bolts. 6. Drain engine coolant from radiator. 3. Fan motor (RH) Cooling fan (RH) 3. Removal and Installation REMOVAL 1. INFOID:0000000003793176 2. 5. Remove cooling fan assembly. 5. "Draining". "Removal and Installation". 4. Refer to CO-8. CAUTION: • Perform this step engine is cold. Fan motor (LH) Mounting rubber Apply on fan motor shaft : Vehicle front 2. Remove the following parts. and move harness to aside. 4. "Exploded View". A.COOLING FAN < ON-VEHICLE REPAIR > COOLING FAN Exploded View INFOID:0000000003793175 JPBIA1687GB 1. and move harness to aside. 7. "Exploded View". Refer to CO-13. "Exploded View". "Components" for symbols not described on the above. "Exploded View". Remove radiator cap adapter and radiator hoses (upper) and radiator pipe (upper) assembly. Fan shroud Cooling fan (LH) : Apply high strength thread locking sealant or equivalent. Refer to GI-4. • Oil level gauge: Refer to EM-96. • Never spill engine coolant on drive belt. Disconnect harness connector from crash zone sensor. • Engine under cover • Air duct (inlet): Refer to EM-26. CO-16 . • Battery and battery tray: Refer to PG-109. Disconnect harness connector from fan motors (RH and LH). 6. and install in the reverse order of removal. • Apply high thread locking sealant on for motor shaft. refer to EC-60. and then remove the cooling fans (RH and LH). • Install each fan in the following position. and assemble in the reverse order of disassembly. CO CAUTION: Only use genuine parts for cooling fan mounting bolt and observe the specified torque (to prevent radiator from being damaged). Be careful not to misassemble them. H Inspection INSPECTION AFTER DISASSEMBLY Cooling Fan Inspect cooling fan for crack or unusual bend. 2. CAUTION: RH and LH cooling fans are different.COOLING FAN < ON-VEHICLE REPAIR > CAUTION: Be careful not to damage or scratch on radiator core. A INSTALLATION Note the following. For details. Disassembly and Assembly DISASSEMBLY 1. replace cooling fan. Remove fan motors (RH and LH). Remove cooling fan mounting nuts. INFOID:0000000003793178 I J K L M N O P CO-17 . Right side Left side : 11 blades : 9 blades F G • Secure the harness tightly to the fan shroud to prevent the fan rotation area from being loose. • If anything is found. NOTE: C Cooling fans are controlled by ECM. INFOID:0000000003793177 D E ASSEMBLY Note the following. "System Diagram". Removal and Installation INFOID:0000000003793180 CAUTION: • When removing water pump assembly. Remove the following parts. 7. Remove drive belt. • After installing water pump. 8. 8. "Exploded View". • Air duct (inlet): Refer to EM-26. Remove idler pulleys. • Never spill engine coolant on drive belt. Timing chain tensioner (primary) Water drain plug (front) O-ring Apply engine coolant 2. "Exploded View". 7. 3. "FENDER PROTECTOR : Exploded View". and move it to aside. A. connect hose and clamp securely. CO-18 . 5. engine mounting bracket (RH) and upper torque rod. be careful not to get engine coolant on drive belt. Refer to EM-12. Refer to CO-8. "Draining". Refer to CO-13. 4. 2. Valve timing control cover (bank 1) O-ring Refer to GI-4. Support oil pan (lower) bottom with transmission jack. Remove engine mounting insulator (RH). Remove reservoir tank of power steering oil pump with piping connected. "Exploded View". CAUTION: • Perform this step when the engine is cold. • Engine cover: Refer to EM-24.WATER PUMP < ON-VEHICLE REPAIR > WATER PUMP Exploded View INFOID:0000000003793179 JPBIA1721GB 1. REMOVAL 1. 6. Refer to EM-67. 4. Refer to ST-34. Valve timing control cover gasket (bank 1) Water pump cover Water pump 3. Drain engine coolant from radiator. 6. Remove reservoir tank of radiator. "Exploded View". • Engine under cover • Front road wheel and tire • Splash guard (RH): Refer to EXT-22. Refer to EM-25. "Exploded View". • Water pump cannot be disassembled and should be replaced as a unit. "Exploded View". "Removal and Installation". then check for leakage using the radiator cap tester (commercial service tool) and the radiator cap tester adapter (commercial service tool). "Components" for symbols in the figure. 5. • Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal. Remove lower mounting bolt (1). b. JPBIA0085ZZ c. and then turn chain tensioner (primary) (3) on the mounting bolt so that plunger (4) is D fully expanded. F G H PBIC4820E I d. Secure a gap between water pump gear and timing chain. and then remove timing chain tensioner (primary). Remove water drain plug (front) on water pump side of cylinder block to drain engine coolant from engine inside. Remove timing chain tensioner (primary) as follows: CO a. it is not dropped from the body E of timing chain tensioner (primary). Loosen upper mounting bolt (2) slowly. Remove upper mounting bolt.WATER PUMP < ON-VEHICLE REPAIR > 9. Remove three water pump mounting bolts. J K L PBIC3576E 12. Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose. CAUTION: Be careful not to drop mounting bolt inside timing chain case. A 10. CAUTION: Be careful not to drop mounting bolt inside timing chain C case. Remove valve timing control cover (bank 1) and water pump cover from front timing chain case. Remove water pump as follows: a. M N O P PBIC1193E CO-19 . NOTE: Even if plunger is fully expanded. by turning crankshaft pulley counterclockwise until timing chain looseness on water pump sprocket becomes maximum. 11. • Remove water pump without causing sprocket to contact timing chain. and pull out water pump. CAUTION: • Pull straight out while preventing vane from contacting socket in installation area. c. PBIC1397E 2. Then. CAUTION: Never allow cylinder block to nip O-rings when installing water pump. CAUTION: Never disassemble water pump. Install water pump. Remove M8 bolts and O-rings from water pump.25 mm (0. a. JLC357B INSTALLATION 1. • Check that timing chain and water pump sprocket are engaged. SLC031B 3. Screw M8 bolts [pitch: 1. Install timing chain tensioner (primary) as follows: Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose. PBIC4820E CO-20 . • Insert water pump by tightening mounting bolts alternately and evenly. • Locate O-ring with white paint mark to engine front side. Install new O-rings to water pump.97 in)] into water pumps upper and lower mounting bolt holes until they reach timing chain case.WATER PUMP < ON-VEHICLE REPAIR > b. • Apply engine oil and engine coolant to O-rings as shown in the figure.0492 in) length: approximately 50 mm (1. alternately tighten each bolt for a half turn. Engine may produce a rattling noise. Also remove traces of old liquid gasket from the mating surface of front timing chain case.0. then rev engine up to 3. f. a : φ2. This indicates that air still remains in the chamber and is not a matter of concern. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to mating surface of water pump cover (1). 6. c. g. Install in the reverse order of removal after this step. Check again that timing chain and water pump sprocket are engaged. F G H JPBIA1774ZZ I h. Hold plunger in the fully compressed position by engaging plunger stopper tab with the tip of ratchet. insert stopper pin (E) through hole of lever into C tensioner body hole (B). 4. D NOTE: Figure shows the example of 1.130 in) J K b. • Apply liquid gasket to the thread of water drain plug (front). To secure lever. Install water drain plug (front) on water pump side of cylinder block. e. Push plunger into the inside of tensioner body. Install valve timing control cover (bank 1) and water pump cover as follows: Before installing. CO d. CAUTION: Attaching should be done within 5 minutes after coating. let idle for three minutes. JPBIA1722ZZ M N 5. • Remove dust and foreign material completely from backside of timing chain tensioner (primary) and E from installation area of rear timing chain case.3. remove all traces of old liquid gasket from mating surface of water pump cover using scraper. Install timing chain tensioner (primary). Use Genuine Liquid Gasket or equivalent.3 mm (0. Tighten mounting bolts. INFOID:0000000003793181 O P Inspection INSPECTION AFTER REMOVAL • Check for badly rusted or corroded water pump body assembly.000 rpm under no load to purge air from the high-pressure chamber of chain tensioner.3 . Use Genuine Liquid Gasket or equivalent. A NOTE: Plunger stopper tab and lever (C) are synchronized. Therefore. a.047 in) diameter thin screwdriver being used as the stopper pin. • The lever parts and the tab are synchronized. CO-21 . Pull plunger stopper tab (A) up (or turn lever downward) so as to remove plunger stopper tab from the ratchet of plunger (D). L c. the JPBIA0118ZZ plunger will be secured under this condition.2 mm (0.091 . • After starting engine.WATER PUMP < ON-VEHICLE REPAIR > b. Remove stopper pin (A). "Inspection". • If anything is found.WATER PUMP < ON-VEHICLE REPAIR > • Check for rough operation due to excessive end play. Refer to CO-8. Visually check that there is no leakage of engine coolant. CO-22 . replace water pump. SLC943A INSPECTION AFTER INSTALLATION • Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the radiator cap tester (commercial service tool). • Start and warm up the engine. A : Never loosen these screw K L M CAUTION: Never disassemble water inlet and thermostat assembly. 5. • Be careful not to spill engine coolant over engine room. Remove reservoir tank of radiator. Clamp H Refer to GI-4. and install in the reverse order of removal.WATER INLET AND THERMOSTAT ASSEMBLY < ON-VEHICLE REPAIR > WATER INLET AND THERMOSTAT ASSEMBLY Exploded View INFOID:0000000003793182 A CO C D E F G JPBIA1688GB 1. Use rag to absorb engine coolant. Drain engine coolant from radiator drain plug at the bottom of radiator. and from water drain plug at the front of cylinder block. Water inlet and thermostat assembly 3. • Never spill engine coolant on drive belt. "Exploded View". CAUTION: • Perform this step when the engine is cold. "Exploded View". N O JPBIA0261ZZ P INSTALLATION Note the following. I Removal and Installation REMOVAL 1. and move it aside. CO-23 . Remove intake valve timing control solenoid valve (bank 2). "Exploded View". INFOID:0000000003793183 J 2. 4. "Components" for symbols in the figure. 4. "Draining" and EM-107. Refer to CO-13. A. Refer to CO-8. Remove water inlet and thermostat assembly (1). Replace them as a unit. if necessary. Gasket Radiator hose (lower) To radiator 2. 3. Refer toEM-52. Disconnect radiator hose (lower) from water inlet and thermostat assembly. "Thermostat".WATER INLET AND THERMOSTAT ASSEMBLY < ON-VEHICLE REPAIR > Inspection INSPECTION AFTER REMOVAL 1. Thermostat (Standard) : Refer to CO-27. Check valve seating condition at ordinary room temperatures. Refer to CO-8. Check valve operation. or measured values are out of the standard. • Start and warm up the engine. It should seat tightly. when valve seating at ordinary room temperature. replace water inlet and thermostat assembly. INFOID:0000000003793184 • If the malfunctioning condition. Visually check that there is no leakage of engine coolant. CO-24 . "Inspection". SLC949A INSPECTION AFTER INSTALLATION • Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the radiator cap tester (commercial service tool). 2. INFOID:0000000003793186 O 4. Refer to CO-8. Radiator hose (upper) C. 7. "Exploded View". Water hose 17. Clamp Water outlet Water connector Clamp 3. 8.WATER OUTLET AND WATER PIPING < ON-VEHICLE REPAIR > WATER OUTLET AND WATER PIPING Exploded View INFOID:0000000003793185 A CO C D E F G H I J JPBIA1691GB 1. To oil cooler L 14. 4. 2. "Draining" and EM-110. Remove engine cover. Remove battery and battery tray. 9. Heater hose 18. 5. 3. N Removal and Installation REMOVAL 1. • Never spill engine coolant on drive belt. Refer to PG-109. To heater core To radiator 12. CAUTION: • Perform this step when the engine is cold. Drain engine coolant from radiator drain plug at the bottom of radiator. Water hose Gasket O-ring K 10. 6. "Disassembly and Assembly". and from water drain plug at the front of cylinder block. Engine coolant temperature sensor A. P CO-25 . Refer to EM-24. "Removal and Installation". To electric throttle control actuator M Refer to GI-4. Water hose 15. Heater pipe 16. Remove air duct (inlet). Clamp B. 11. D. air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly. "Components" for symbols in the figure. "Exploded View". Heater hose Clamp Gasket 2. Refer to EM-26. Water bypass pipe 13. Visually check that there is no leakage of engine coolant.WATER OUTLET AND WATER PIPING < ON-VEHICLE REPAIR > 5. • Start and warm up the engine. • When inserting water bypass pipe and heater pipe into water connector. "Exploded View". "Exploded View" (VQ35DE). Refer to EM-67. 11. "Exploded View" (VQ35DE). Remove CVT fluid charging pipe and CVT fluid level gauge. apply neutral detergent to O-ring. Remove water hoses and heater hoses. Remove water outlet. INSTALLATION Note the following. heater pipe. CAUTION: Be careful not to damage engine coolant temperature sensor. "Exploded View" (VQ25DE) or TM-157. "Inspection". 8. Remove engine coolant temperature sensor as necessary. and move harness to aside. Refer to TM-319. Move CVT control cable aside. water bypass pipe and water connector. Refer to TM-332. 6. 12. Remove radiator hose (upper) from water outlet. Disconnect harness connectors. 10. 9. Refer to CO-8. Inspection INSPECTION AFTER INSTALLATION INFOID:0000000003793187 • Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the radiator cap tester (commercial service tool). Remove vacuum pipe (front) mounting bolt from water outlet. • Securely insert each hose. "Exploded View" (VQ25DE) or TM-168. and install clamp at a position where it does not interfere with the pipe bulge. and install in the reverse order of removal. 7. CO-26 . 8) INFOID:0000000003793190 F Thermostat Standard G Valve opening temperature Maximum valve lift Valve closing temperature 80. 1.22.57. psi) E Cap relief pressure Leakage test pressure 122. kg/cm2.83.182°F) 8.5.1. 1.2 .0) 108 (1.2 .3 . 22.5.1.8 (3/4) Radiator Standard Limit D INFOID:0000000003793189 Unit: kPa (bar. 1.1 (8) 0. 15.6 mm/95°C (0.SERVICE DATA AND SPECIFICATIONS (SDS) < SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Periodical Maintenance Specification ENGINE COOLANT CAPACITY (APPROXIMATE) Unit: (lmp qt) INFOID:0000000003793188 A CO C Engine coolant capacity (With reservoir tank at “MAX” level) Reservoir tank 9.6.6) 157 (1.7 (1.1.5°C (177 .1.5 .7 .151.339 in/203°F) 77°C (171°F) H I J K L M N O P CO-27 . 17.