ENGINE

ENGINE COOLING SYSTEM

SECTION CO CO

E
CONTENTS
MR20DE ON-VEHICLE REPAIR ................................. 13 F

FUNCTION DIAGNOSIS ............................... 3 RADIATOR ........................................................ 13

Exploded View .........................................................13 G
DESCRIPTION .................................................... 3 Removal and Installation .........................................13
Engine Cooling System ............................................. 3 Inspection ................................................................15
Engine Cooling System Schematic ........................... 4
COOLING FAN .................................................. 16 H
SYMPTOM DIAGNOSIS ............................... 5 Exploded View .........................................................16
Removal and Installation .........................................16
OVERHEATING CAUSE ANALYSIS .................. 5 Disassembly and Assembly .....................................17 I
Troubleshooting Chart ............................................... 5 Inspection ................................................................17
PRECAUTION ............................................... 7 WATER PUMP .................................................. 18
Exploded View .........................................................18 J
PRECAUTIONS ................................................... 7
Removal and Installation .........................................18
Precaution for Supplemental Restraint System
Inspection ................................................................18
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
K
SIONER" ................................................................... 7 THERMOSTAT .................................................. 20
Precaution Necessary for Steering Wheel Rota- Exploded View .........................................................20
tion after Battery Disconnect ..................................... 7 Removal and Installation .........................................20
L
Inspection ................................................................21
PREPARATION ............................................ 8
WATER OUTLET .............................................. 22
PREPARATION ................................................... 8 Exploded View .........................................................22 M
Commercial Service Tools ....................................... 8
Removal and Installation .........................................23
ON-VEHICLE MAINTENANCE ..................... 9 Inspection ................................................................24

SERVICE DATA AND SPECIFICATIONS N

ENGINE COOLANT ............................................ 9
Inspection .................................................................. 9 (SDS) ............................................................ 25
Draining ..................................................................... 9
Refilling ................................................................... 10
SERVICE DATA AND SPECIFICATIONS O
Flushing ................................................................... 11 (SDS) ................................................................. 25
Periodical Maintenance Specification ......................25
RADIATOR .........................................................12 Radiator ...................................................................25 P
Thermostat ..............................................................25
RADIATOR CAP ........................................................ 12 Water Control Valve (Models with Water Control
RADIATOR CAP : Inspection .................................. 12 Valve) ......................................................................25
RADIATOR ................................................................ 12 VQ25DE, VQ35DE
RADIATOR : Inspection .......................................... 12
FUNCTION DIAGNOSIS .............................. 26

Revision: 2008 December CO-1 J32

DESCRIPTION ................................................... 26 ON-VEHICLE REPAIR ............................... 36
Engine Cooling System ......................................... 26
Engine Cooling System Schematic ...................... 26 RADIATOR ........................................................ 36
Exploded View ........................................................ 36
SYMPTOM DIAGNOSIS ............................. 27 Removal and Installation ......................................... 36
Inspection ................................................................ 38
OVERHEATING CAUSE ANALYSIS ................ 27
Troubleshooting Chart ........................................... 27 COOLING FAN .................................................. 39
Exploded View ........................................................ 39
PRECAUTION ............................................. 29 Removal and Installation ......................................... 39
Disassembly and Assembly .................................... 40
PRECAUTIONS ................................................. 29 Inspection ................................................................ 40
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- WATER PUMP ................................................... 41
SIONER" ................................................................. 29 Exploded View ........................................................ 41
Liquid Gasket ......................................................... 29 Removal and Installation ......................................... 41
Inspection ................................................................ 44
PREPARATION ........................................... 31
WATER INLET AND THERMOSTAT ASSEM-
PREPARATION ................................................. 31 BLY .................................................................... 46
Special Service Tool ............................................... 31
Exploded View ........................................................ 46
Commercial Service Tools .................................... 31
Removal and Installation ......................................... 46
ON-VEHICLE MAINTENANCE ................... 32 Inspection ................................................................ 47

ENGINE COOLANT ........................................... 32 WATER OUTLET AND WATER PIPING .......... 48

Inspection ............................................................... 32 Exploded View ........................................................ 48
Draining .................................................................. 32 Removal and Installation ......................................... 48
Refilling ................................................................... 33 Inspection ................................................................ 49
Flushing .................................................................. 34 SERVICE DATA AND SPECIFICATIONS
RADIATOR ........................................................ 35 (SDS) .......................................................... 50
RADIATOR CAP ....................................................... 35 SERVICE DATA AND SPECIFICATIONS
RADIATOR CAP : Inspection ................................. 35 (SDS) ................................................................. 50
Periodical Maintenance Specification ..................... 50
RADIATOR ................................................................ 35 Radiator .................................................................. 50
RADIATOR : Inspection .......................................... 35 Thermostat .............................................................. 50

Revision: 2008 December CO-2 J32

 DESCRIPTION
< FUNCTION DIAGNOSIS > [MR20DE]

FUNCTION DIAGNOSIS A
DESCRIPTION
Engine Cooling System INFOID:0000000003801928
CO

Except for China

C

JPBIA2860GB J
For China
K

JPBIA2495GB

Revision: 2008 December CO-3 J32

 DESCRIPTION
< FUNCTION DIAGNOSIS > [MR20DE]
Engine Cooling System Schematic INFOID:0000000003801929

Except for China

JPBIA2861GB

For China

JPBIA2496GB

Revision: 2008 December CO-4 J32

 OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [MR20DE]

SYMPTOM DIAGNOSIS A
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart INFOID:0000000003801930
CO

Symptom Check items

C
Water pump malfunction Worn or loose drive belt
Thermostat and water con-
—
trol valve stuck closed
D
Dust contamination or pa-
Poor heat transfer —
Damaged fins per clogging
Physical damage E
Clogged radiator cooling Excess foreign material
tube (rust, dirt, sand, etc.)
Cooling fan does not oper- F
ate
Reduced air flow High resistance to fan rota- Fan assembly —
tion
G
Damaged fan blades
Damaged radiator shroud — — —

Cooling sys- Improper engine coolant H

— — —
tem parts mixture ratio
malfunction Poor engine coolant quality — Engine coolant viscosity —
Loose clamp I
Cooling hose
Cracked hose
Water pump Poor sealing
J
Loose
Reservoir tank cap
Poor sealing
Engine coolant leakage
O-ring for damage, deterio- K
Insufficient engine coolant ration or improper fitting
Radiator
Cracked radiator tank
Cracked radiator core L
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leakage into M
Overflowing reservoir tank Cylinder head gasket deteri-
cooling system
oration

Revision: 2008 December CO-5 J32

 OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [MR20DE]
Symptom Check items
High engine rpm under no
load
Driving in low gear for ex-
Abusive driving
tended 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 paper
Blocked or restricted air clogging —
flow
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp

Revision: 2008 December CO-6 J32

 PRECAUTIONS
< PRECAUTION > [MR20DE]

PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT CO
PRE-TENSIONER" INFOID:0000000004221779

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING: D
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. E
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIR BAG”.
F
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the H
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the I
battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect
INFOID:0000000004221780
J

NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-
K
tion, then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work. L
If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
This vehicle is equipped with a push-button ignition switch and a steering lock unit.
If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. M
If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure
below before starting the repair operation.
OPERATION PROCEDURE N
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged. O
2. Turn the push-button ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon- P
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT-III.

Revision: 2008 December CO-7 J32

 PREPARATION
< PREPARATION > [MR20DE]

PREPARATION
PREPARATION
Commercial Service Tools INFOID:0000000003801934

Tool name Description

Radiator cap tester Checking radiator and radiator cap

PBIC1982E

Radiator cap tester adapter Adapting radiator cap tester to radiator cap
and water outlet (front) filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

S-NT564

Revision: 2008 December CO-8 J32

 ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [MR20DE]

ON-VEHICLE MAINTENANCE A
ENGINE COOLANT
Inspection INFOID:0000000003801935
CO

LEVEL
• Check that the reservoir tank engine coolant level is within the C
“MIN” to “MAX” when the engine is cool.

A : MAX
B : MIN
D

• Adjust the engine coolant level if necessary.

E

JPBIA0102ZZ
F
LEAKAGE
• To check for leakage, apply pressure to the cooling system with the
radiator cap tester (commercial service tool) (A) and the radiator G
cap tester adapter (commercial service tool) (B).

Testing pressure: Refer to CO-25, "Radiator". H

WARNING:
Never remove radiator cap when engine is hot. Serious burns
may occur from high-pressure engine coolant escaping from I
radiator.
CAUTION:
Higher test pressure than specified may cause radiator dam- PBIC5121J

age. J
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
• If anything is found, repair or replace damaged parts. K
Draining INFOID:0000000003801936

WARNING: L
• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine
coolant escaping from radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres- M
sure. Then turn it all the way.
1. Remove engine under cover.
2. Open radiator drain plug (1) at the bottom of radiator, and then N
remove radiator cap.

: Vehicle front
O
CAUTION:
Perform this step when engine is cold.
• When draining all of engine coolant in the system, open water P
drain plugs on cylinder block. Refer to EM-91, "Disassembly
and Assembly".
JPBIA2225ZZ

3. Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing.
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to CO-11, "Flushing".

Revision: 2008 December CO-9 J32

 ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [MR20DE]
Refilling INFOID:0000000003801937

1. Install reservoir tank if removed and radiator drain plug.

CAUTION:
Be sure to clean drain plug and install with new O-ring.

Radiator drain plug : Refer to CO-13, "Exploded View".

• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-91, "Disassem-
bly and Assembly".
2. Check that each hose clamp has been firmly tightened.
3. Fill radiator to specified level.
CAUTION:
Never adhere the engine coolant to electronic equipments
(alternator etc.).
• Pour coolant slowly of less than 2 (1-3/4 Imp qt) a
minute to allow air in system to escape.
• Use Genuine NISSAN Engine Coolant or equivalent in its
quality mixed with water (distilled or demineralized). Refer
to MA-8, "Fluids and Lubricants".

Engine coolant capacity JPBIA0412ZZ

(With reservoir tank at “MAX” level)
Refer to CO-25, "Periodical Maintenance Specification".

4. Refill reservoir tank to “MAX” level line with engine coolant.

A : MAX
B : MIN

Reservoir tank engine coolant capacity

(At “MAX” level)
Refer to CO-25, "Periodical Maintenance Specification".

JPBIA0102ZZ

5. Install radiator cap.

6. Warm up engine until opening thermostat. Standard for warming-up time is approximately 10 minutes at
3,000 rpm.
• Check thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.
CAUTION:
Watch water temperature gauge so as not to overheat engine.
7. Stop the engine and cool down to less than approximately 50°C (122°F).
• Cool down using fan to reduce the time.
• If necessary, refill radiator up to filler neck with engine coolant.
CAUTION:
Never adhere the engine coolant to electronic equipments (alternator etc.).
8. Refill reservoir tank to “MAX” level line with engine coolant.
9. Repeat steps 8 through 10 two or more times with radiator cap installed until engine coolant level no
longer drops.
10. Check cooling system for leakage with engine running.
11. Warm up the engine, and check for sound of engine coolant flow while running engine from idle up to
3,000 rpm with heater temperature controller set at several position between “COOL” and “WARM”.
• Sound may be noticeable at heater unit.
12. Repeat step 14 three times.
13. If sound is heard, bleed air from cooling system by repeating step 8 through 10 until reservoir tank level no
longer drops.

Revision: 2008 December CO-10 J32

 ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [MR20DE]
Flushing INFOID:0000000003801938

A
1. Install reservoir tank if removed and radiator drain plug.
CAUTION:
Be sure to clean drain plug and install with new O-ring. CO

Radiator drain plug : Refer to CO-13, "Exploded View".

• If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-91, "Disassem- C
bly and Assembly".
2. Fill radiator and reservoir tank with water and reinstall radiator cap.
3. Run the engine and warm it up to normal operating temperature. D
4. Rev the engine two or three times under no-load.
5. Stop the engine and wait until it cools down.
E
6. Drain water from the system. Refer to CO-9, "Draining".
7. Repeat steps 1 through 9 until clear water begins to drain from radiator.
F

Revision: 2008 December CO-11 J32

 RADIATOR
< ON-VEHICLE MAINTENANCE > [MR20DE]
RADIATOR
RADIATOR CAP
RADIATOR CAP : Inspection INFOID:0000000003801939

• Check valve seat (A) of radiator cap.

- Check that valve seat is swollen to the extent that the edge of the
plunger (B) cannot be seen when watching it vertically from the
top.
- Check that 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.
- Check that there are no unusualness in the opening and closing
conditions of negative-pressure valve.

JPBIA1961ZZ

• Check radiator cap relief pressure.

Standard and Limit : Refer to CO-25, "Radiator".

- When connecting radiator cap to the radiator cap tester (commer-
cial service tool) (A) and the radiator cap tester adapter (commer-
cial service tool) (B), apply engine coolant to the cap seal surface.

PBIC5122J

• Replace radiator cap if there is an unusualness related to the above three.

CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
RADIATOR
RADIATOR : Inspection INFOID:0000000003801940

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

CAUTION:
• Be careful not to bend or damage radiator fins.
• When radiator is cleaned without removal, remove all surrounding parts such as radiator cooling fan
assembly and horns. Then tape harness and harness connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing if any stains no longer flow out from radiator.
4. Blow air into the back side of radiator core vertically downward.
• Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71 psi) and keep distance more than 30 cm
(11.81 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.

Revision: 2008 December CO-12 J32

 RADIATOR
< ON-VEHICLE REPAIR > [MR20DE]

ON-VEHICLE REPAIR A
RADIATOR
Exploded View INFOID:0000000003801941
CO

REMOVAL
C

M
JPBIA2216GB

1. Reservoir tank cap 2. Reservoir tank 3. Clamp N

4. Reservoir tank hose 5. Radiator cap 6. Radiator pipe (upper)
7. Clamp 8. Radiator hose (upper) 9. Radiator hose (upper)
10. O-ring 11. Drain plug 12. Water drain hose O
13. Mounting rubber (upper) 14. Radiator upper clip 15. Radiator
16. Mounting rubber (lower) 17. Clamp 18. CVT fluid cooler hose
19. CVT fluid cooler hose 20. Grommet 21. Cooling fan assembly P
22. Radiator hose (lower)
A. To water outlet B. To transaxle assembly C. To water inlet
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000003801942

REMOVAL

Revision: 2008 December CO-13 J32

 RADIATOR
< ON-VEHICLE REPAIR > [MR20DE]
WARNING:
• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine
coolant escaping from radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres-
sure. Then turn it all the way.
1. Remove the following parts
• Engine under cover
• Air duct (inlet): Refer to EM-27, "Exploded View".
• Horn: Refer to HRN-6, "Exploded View".
• Hood lock: Refer to DLK-250, "Exploded View" (WITH INTELLIGENT KEY SYSTEM) or DLK-441,
"Exploded View" (WITHOUT INTELLIGENT KEY SYSTEM).
2. Drain engine coolant from radiator. Refer to CO-9, "Draining".
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belts.
3. Disconnect reservoir tank hose from radiator pipe (upper).
4. Disconnect CVT fluid cooler hoses from radiator.
• Insert blind plug to avoid leakage of CVT fluid.
5. Remove condenser. Refer to HA-52, "Exploded View".
CAUTION:
Be careful not to damage condenser core.
6. Remove each radiator hoses (upper) and radiator pipe (upper) assembly.
CAUTION:
Never spill engine coolant on drive belt.
7. Remove radiator hose (lower).
8. Remove each radiator upper clips (2) by pulling the tabs (A) out-
side to release the lock (B) and then remove each mounting rub-
bers (upper) (1).

C : Mounting pin
: Vehicle front

CAUTION:
Never pull the tabs outside excessively to prevent it from
damping.
9. Lift up and remove radiator from front of radiator core support. JPBIA1689ZZ
CAUTION:
Be careful not to damage or scratch on radiator core.
INSTALLATION
Note the following, and install in the reverse order of removal.
Radiator Upper Clip
Install each radiator upper clips on radiator core connection as follows:
1. Install each mounting rubbers (upper) (1) on mounting pins (A)
of radiator.

: Vehicle front

2. Align each radiator upper clips (2) with radiator core connection
(B), then insert each radiator upper clips straight into radiator
core connections until a click is heard.
3. After connecting each radiator upper clips, use the following
method to check it is fully connected.
• Visually confirm that each radiator upper clips are connected JPBIA1690ZZ
to radiator core connections.
• Move each radiator upper clips and the radiator forward and backward to check they are securely con-
nected.

Revision: 2008 December CO-14 J32

 RADIATOR
< ON-VEHICLE REPAIR > [MR20DE]
Inspection INFOID:0000000003801944

A
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). Refer to CO-9, "Inspection". CO
• Start and warm up the engine. Visually check that there is no leakage of engine coolant and CVT fluid.

Revision: 2008 December CO-15 J32

 COOLING FAN
< ON-VEHICLE REPAIR > [MR20DE]
COOLING FAN
Exploded View INFOID:0000000003801945

JPBIA1687GB

1. Fan motor (LH) 2. Fan motor (RH) 3. Fan shroud

4. Mounting rubber 5. Cooling fan (RH) 6. Cooling fan (LH)
A. Apply on fan motor shaft
: Vehicle front
: Apply high strength thread locking sealant or equivalent.

Refer to GI-4, "Components" for symbols not described on the above.

Removal and Installation INFOID:0000000003801946

REMOVAL
1. Remove the following parts.
• Engine under cover
• Air duct (inlet): Refer to EM-27, "Exploded View".
2. Drain engine coolant from radiator. Refer to CO-9, "Draining".
CAUTION:
• Perform this step engine is cold.
• Never spill engine coolant on drive belts.
3. Remove each radiator hose (upper) and radiator pipe (upper) assembly. Refer to CO-13, "Exploded
View".
4. Disconnect harness connector from fan motor (RH and LH), and move harness to aside.
5. Disconnect harness connector from crash zone sensor and move harness to aside. Refer to SR-18,
"Exploded View".
6. Remove cooling fan assembly.
CAUTION:
Be careful not to damage or scratch on radiator core when removing.

Revision: 2008 December CO-16 J32

 COOLING FAN
< ON-VEHICLE REPAIR > [MR20DE]
INSTALLATION
Note the following, and install in the reverse order of removal. A
CAUTION:
Only use genuine parts for fan shroud mounting bolt and observe the specified torque (to prevent
radiator from being damaged). CO
NOTE:
Cooling fans are controlled by ECM. For details, refer to EC-60, "System Diagram" (TYPE 1) or EC-408, "Sys-
tem Diagram" (TYPE 2).
C
Disassembly and Assembly INFOID:0000000003801947

DISASSEMBLY D
1. Remove cooling fan mounting nuts, and then remove the cooling fans (RH and LH).
2. Remove fan motors (RH and LH).
E
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
CAUTION:
RH and LH cooling fans are different. Be careful not to misassemble them. F
• Install each fan in the following position.

Right side : 11 blades G

Left side : 9 blades
• Secure the harness to the fan shroud to prevent the fan rotation area from being loose.
• Apply high thread locking sealant on fan motor shaft. H

Inspection INFOID:0000000003801948

I
INSPECTION AFTER DISASSEMBLY
Cooling Fan
Inspect cooling fan for crack or unusual bend. J
• If anything is found, replace cooling fan.

Revision: 2008 December CO-17 J32

 WATER PUMP
< ON-VEHICLE REPAIR > [MR20DE]
WATER PUMP
Exploded View INFOID:0000000003801949

KBIA4510J

1. Water pump 2. Gasket

Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000003801950

REMOVAL
1. Drain engine coolant from radiator. Refer to CO-9, "Draining".
CAUTION:
Perform this step when the engine is cold.
2. Remove drive belts. Refer to EM-16, "Removal and Installation".
3. Remove water pump.
• Engine coolant leakage from cylinder block, so have a receptacle 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.
INSTALLATION
Install in the reverse order of removal.
Inspection INFOID:0000000003801951

INSPECTION AFTER REMOVAL

• Check visually that there is no significant dirt or rusting on water
pump body and vane (A).
• Check that there is no looseness in vane shaft, and that it turns
smoothly when rotated by hand.
• Replace water pump, if necessary.

PBIC3313J

INSPECTION AFTER INSTALLATION

Revision: 2008 December CO-18 J32

 WATER PUMP
< ON-VEHICLE REPAIR > [MR20DE]
• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-9, "Inspection". A
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.

CO

Revision: 2008 December CO-19 J32

 THERMOSTAT
< ON-VEHICLE REPAIR > [MR20DE]
THERMOSTAT
Exploded View INFOID:0000000003801952

PBIC3549J

1. Gasket 2. Thermostat housing 3. Rubber ring

4. Thermostat 5. Water inlet 6. Radiator hose (lower)
A. To radiator
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000003801953

REMOVAL
1. Drain engine coolant from radiator. Refer to CO-9, "Draining".
CAUTION:
Perform this step when engine is cold.
2. Remove air duct (inlet). Refer to EM-27, "Exploded View".
3. Add paint mark, then disconnect radiator hose (lower) from water inlet. Refer to CO-13, "Exploded View".
4. Remove water inlet and thermostat.
• Engine coolant leakage from cylinder block, so have a receptacle ready below.
5. Remove thermostat housing with the following procedure:
a. Remove A/C compressor with A/C piping connected, and temporarily fasten it on vehicle with a rope.
Refer to HA-43, "Exploded View".
b. Remove water pump. Refer to CO-18, "Exploded View".
c. Remove alternator. Refer to CHG-25, "MR20DE : Exploded View".
INSTALLATION
Note the following, and install in the reverse order of removal.
Thermostat

Revision: 2008 December CO-20 J32

 THERMOSTAT
< ON-VEHICLE REPAIR > [MR20DE]
• Install thermostat with making rubber ring (1) groove fit to thermo-
stat flange (A) with the whole circumference. A

CO

PBIC3315J

D
• Install thermostat (1) with jiggle valve (A) facing upwards.

2 : Thermostat housing E

G
PBIC3548J

Inspection INFOID:0000000003801954 H

INSPECTION AFTER REMOVAL

Thermostat I
• 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. J
• 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 K
temperature and check the valve closing temperature.

Standard: Refer to CO-25, "Thermostat". L

• If out of the standard, replace thermostat. PBIC3314J

INSPECTION AFTER INSTALLATION M

• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-9, "Inspection".
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.
N

Revision: 2008 December CO-21 J32

 WATER OUTLET
< ON-VEHICLE REPAIR > [MR20DE]
WATER OUTLET
Exploded View INFOID:0000000003801955

Except for China

JPBIA2862GB

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

4. Water control valve 5. Rubber ring 6. Clamp
7. Radiator hose (upper) 8. Clamp 9. Heater hose
10. Water outlet 11. Heater hose
A. To heater B. Models with water control valve C. To radiator
: Engine front
Refer to GI-4, "Components" for symbols in the figure.

Revision: 2008 December CO-22 J32

 WATER OUTLET
< ON-VEHICLE REPAIR > [MR20DE]
For China
A

CO

H
PBIC4699E

1. Engine coolant temperature sensor 2. Rubber ring 3. Water control valve

4. Gasket 5. Water hose 6. Gasket I
7. Water hose 8. Water outlet 9. Heater hose
10. Heater hose 11. Radiator hose (upper)
A. To heater B. To electric throttle control actuator C. To radiator J
: Engine front
Refer to GI-4, "Components" for symbols in the figure.
K
Removal and Installation INFOID:0000000003801956

REMOVAL L
1. Drain engine coolant from radiator. Refer to CO-9, "Draining".
CAUTION:
• Perform this step when engine is cold. M
• Never spill engine coolant on drive belts.
2. Remove air duct (inlet) and air cleaner cases (upper and lower) assembly. Refer to EM-27, "Exploded
View". N
3. Disconnect radiator hose (upper). Refer to CO-13, "Exploded View".
4. Disconnect harness connector from engine coolant temperature sensor.
5. Remove water hoses (for China). O
6. Remove heater hoses.
7. Remove water outlet.
P
8. Remove engine coolant temperature sensor from water outlet, if necessary.
INSTALLATION
Note the following, and install in the reverse order of removal.
Water Control Valve (Models with Water Control Valve)

Revision: 2008 December CO-23 J32

 WATER OUTLET
< ON-VEHICLE REPAIR > [MR20DE]
• Install water control valve with making rubber ring (1) groove fit to
water control valve flange (A) with the whole circumference.

PBIC4682E

• Install water control valve (2) with the arrow (A) facing up and the
frame center part (B) facing upwards.

1 : Water outlet

PBIC3319J

Inspection INFOID:0000000003801957

INSPECTION AFTER REMOVAL

Water Control Valve (Models with Water Control Valve)
• Place a thread (A) so that it is caught in the valves of water control
valve (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 continuous valve lifting toward maxi-
mum valve lift.
NOTE:
The maximum valve lift amount standard temperature for water
control valve is the reference value.
• After checking the maximum valve lift amount, lower the water
PBIC3314J
temperature and check the valve closing temperature.

Standard: Refer to CO-25, "Water Control Valve (Models

with Water Control Valve)".
• If out of the standard, replace water control valve.
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). Refer to CO-9, "Inspection".
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.

Revision: 2008 December CO-24 J32

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [MR20DE]

SERVICE DATA AND SPECIFICATIONS (SDS) A

SERVICE DATA AND SPECIFICATIONS (SDS)
Periodical Maintenance Specification INFOID:0000000003801958
CO

ENGINE COOLANT CAPACITY (APPROXIMATE)

Unit: (Imp qt) C
Engine coolant capacity (With reservoir tank at “MAX” level) 7.8 (6-7/8)
Reservoir tank engine coolant capacity (At “MAX” level) 0.8 (3/4)
D
Radiator INFOID:0000000003801959

Unit: kPa (bar, kg/cm2, psi) E

Standard 122.3 - 151.7 (1.2 - 1.5, 1.2 - 1.5, 17.7 - 22.0)
Cap relief pressure
Limit 108 (1.1, 1.1, 15.6)
Leakage testing pressure 157 (1.57, 1.6, 22.8) F

Thermostat INFOID:0000000003801960

G
Standard

Valve opening temperature 80.5 - 83.5°C (177 - 182°F)

Maximum valve lift 8.0 mm/95°C (0.315 in/203°F) H
Valve closing temperature 77°C (171°F)

Water Control Valve (Models with Water Control Valve) INFOID:0000000003801961 I

Standard

Valve opening temperature 93.5 - 96.5°C (200 - 206°F) J

Maximum valve lift 8.0 mm/108°C (0.315 in/226°F)
Valve closing temperature 90°C (194°F)
K

Revision: 2008 December CO-25 J32

 DESCRIPTION
< FUNCTION DIAGNOSIS > [VQ25DE, VQ35DE]

FUNCTION DIAGNOSIS
DESCRIPTION
Engine Cooling System INFOID:0000000003801962

JPBIA1682GB

Engine Cooling System Schematic INFOID:0000000003801963

JPBIA1683GB

Revision: 2008 December CO-26 J32

 OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [VQ25DE, VQ35DE]

SYMPTOM DIAGNOSIS A
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart INFOID:0000000003801964
CO

Symptom Check items

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

Revision: 2008 December CO-27 J32

 OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS > [VQ25DE, VQ35DE]
Symptom Check items
High engine rpm under no
load
Driving in low gear for ex-
Abusive driving
tended time
Driving at extremely high
speed
— Overload on engine
Powertrain system malfunc-
tion
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 paper
Blocked or restricted air clogging —
flow
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp

Revision: 2008 December CO-28 J32

 PRECAUTIONS
< PRECAUTION > [VQ25DE, VQ35DE]

PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT CO
PRE-TENSIONER" INFOID:0000000004221781

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING: D
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. E
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIR BAG”.
F
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the H
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the I
battery, and wait at least 3 minutes before performing any service.
Liquid Gasket INFOID:0000000003801966
J
REMOVAL OF LIQUID GASKET SEALING
• After removing mounting nuts and bolts, separate the mating sur-
face using the seal cutter [SST: KV10111100] (A) and remove old K
liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces. L
• Tap (B) the seal cutter [SST: KV10111100] to insert it, and then
slide (C) it by tapping on the side as shown in the figure.
• In areas where seal cutter [SST: KV10111100] is difficult to use,
use a plastic hammer to lightly tap the parts, to remove it. M
CAUTION:
If for some unavoidable reason tool such as a screwdriver is
JPBIA0052ZZ
used, be careful not to damage the mating surfaces. N
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper (A), remove old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface. O
• Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur- P
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.

JPBIA0053ZZ

Revision: 2008 December CO-29 J32

 PRECAUTIONS
< PRECAUTION > [VQ25DE, VQ35DE]
3. Attach liquid gasket tube to the tube presser (commercial ser-
vice tool).
Use Genuine Liquid Gasket or equivalent.
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions.
• If there is a groove for the liquid gasket application, apply liq-
uid gasket to the groove.

EMA0622D

• As for the bolt holes (B), normally apply liquid gasket inside
the holes. Occasionally, it should be applied outside the holes.
Check to read the text of service manual.

A : Groove
: Inside

• Within five minutes of liquid gasket application, install the mat-

ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Never retighten after mounting bolts and nuts the installation.
JPBIA0010ZZ
• After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe them.

Revision: 2008 December CO-30 J32

 PREPARATION
< PREPARATION > [VQ25DE, VQ35DE]

PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000003801967
CO

Tool number
Description C
Tool name
KV10111100 Removing water pump cover
Seal cutter
D

E
NT046

Commercial Service Tools INFOID:0000000003801968 F

Tool name Description

G
Tube presser Pressing the tube of liquid gasket

I
S-NT052

Radiator cap tester Checking radiator and radiator cap

J

PBIC1982E

Radiator cap tester adapter Adapting radiator cap tester to radiator cap L
and radiator pipe (upper) filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia. M
Unit: mm (in)

S-NT564 N

Revision: 2008 December CO-31 J32

 ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [VQ25DE, VQ35DE]

ON-VEHICLE MAINTENANCE
ENGINE COOLANT
Inspection INFOID:0000000003801969

LEVEL
• Check if the reservoir tank engine coolant level is within the “MIN”
to “MAX” when the engine is cool.

A : MAX
B : MIN
• Adjust the engine coolant level if necessary.

JPBIA0102ZZ

LEAKAGE
• To check for leakage, apply pressure to the cooling system with the
radiator cap tester (commercial service tool) (A) and radiator cap
tester adapter (commercial service tool) (B).

Testing pressure : Refer to CO-50, "Radiator".

WARNING:
Never remove radiator cap when engine is hot. Serious burns
could occur from high-pressure engine coolant escaping from
radiator.
CAUTION:
Higher test pressure than specified may cause radiator dam- PBIC5121J

age.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
• If anything is found, repair or replace damaged parts.
Draining INFOID:0000000003801970

WARNING:
• To avoid being scalded, never change engine coolant when the engine is hot.
• Wrap a thick cloth around radiator cap and carefully remove radiator cap. First, turn radiator cap a
quarter of a turn to release built-up pressure. Then turn radiator cap all the way.
1. Remove engine under cover.
2. Open radiator drain plug (1) at the bottom of radiator, and then
remove radiator cap.

: Vehicle front

JPBIA2225ZZ

When draining all of engine coolant in the system, open water drain plugs on cylinder block. Refer
to EM-235, "Disassembly and Assembly".
3. Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing.

Revision: 2008 December CO-32 J32

 ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [VQ25DE, VQ35DE]
4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush the engine cooling system. Refer to CO-34, "Flushing". A
Refilling INFOID:0000000003801971

1. Install reservoir tank if removed and radiator drain plug. CO

CAUTION:
Be sure to clean drain plug and install with new O-ring.
C
Tightening torque : Refer to CO-36, "Exploded View".
If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-235, "Dis-
assembly and Assembly". D
2. Check that each hose clamp has been firmly tightened.
3. Remove air duct assembly and air cleaner cases (upper and lower) assembly. Refer to EM-150,
"Exploded View". E
4. Disconnect heater hose (1) at the position ( ) in the figure.

: Vehicle front F

H
JPBIA2226ZZ

5. Fill radiator to specified level. I

CAUTION:
Never adhere the engine coolant to electronic equipments.
(alternator etc.)
• Pour engine coolant through engine coolant filler neck J
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.
• When engine coolant overflows disconnected heater K
hose, connect heater hose, and continue filling the engine
coolant.
• Use Genuine NISSAN Engine Coolant or equivalent in its
L
quality mixed with water (distilled or demineralized). Refer
to MA-8, "Fluids and Lubricants". JPBIA0412ZZ

Engine coolant capacity M

(With reservoir tank at “MAX” level)
Refer to CO-50, "Periodical Maintenance Specification".
N
6. Refill reservoir tank to “MAX” level line with engine coolant.

A : MAX
O
B : MIN

Reservoir tank engine coolant capacity P

(At “MAX” level)
Refer to CO-50, "Periodical Maintenance Specification".

JPBIA0102ZZ

7. Install air duct assembly and air cleaner cases (upper and lower) assembly. Refer to EM-150, "Exploded
View".

Revision: 2008 December CO-33 J32

 ENGINE COOLANT
< ON-VEHICLE MAINTENANCE > [VQ25DE, VQ35DE]
8. Install radiator cap.
9. Warm up engine until opening thermostat. Standard for warming-up time is approximately 10 minutes at
3,000 rpm.
• Check thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.
CAUTION:
Watch water temperature gauge so as not to overheat engine.
10. Stop the engine and cool down to less than approximately 50°C (122°F).
• Cool down using fan to reduce the time.
• If necessary, refill radiator up to filler neck with engine coolant.
CAUTION:
Never adhere the engine coolant to electronic equipments. (alternator etc.)
11. Refill reservoir tank to “MAX” level line with engine coolant.
12. Repeat steps 8 through 11 two or more times with radiator cap installed until engine coolant level no
longer drops.
13. Check cooling system for leakage with engine running.
14. Warm up the engine, and check for sound of engine coolant flow while running engine from idle up to
3,000 rpm with heater temperature controller set at several position between “COOL” and “WARM”.
• Sound may be noticeable at heater unit.
15. Repeat step 14 three times.
16. If sound is heard, bleed air from cooling system by repeating step 5, and steps from 8 to 15 until engine
coolant level no longer drops.
Flushing INFOID:0000000003801972

1. Install reservoir tank if removed and radiator drain plug.

CAUTION:
Be sure to clean drain plug and install with new O-ring.

Tightening torque : Refer to CO-36, "Exploded View".

If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-235, "Dis-
assembly and Assembly".
2. Remove air duct assembly and air cleaner cases (upper and lower) assembly. Refer to EM-150,
"Exploded View".
3. Disconnect heater hose (1) at the position ( ) in the figure.

: Vehicle front

JPBIA2226ZZ

4. Fill radiator and reservoir tank with water and reinstall radiator cap.
CAUTION:
Never adhere the water to electronic equipments. (alternator etc.)
• When water overflows disconnected heater hose, connect heater hose, and continue filling the
water.
5. Run the engine and warm it up to normal operating temperature.
6. Rev the engine two or three times under no-load.
7. Stop the engine and wait until it cools down.
8. Drain water from the system. Refer to CO-32, "Draining".
9. Repeat steps 1 through 8 until clear water begins to drain from radiator.

Revision: 2008 December CO-34 J32

 RADIATOR
< ON-VEHICLE MAINTENANCE > [VQ25DE, VQ35DE]
RADIATOR
A
RADIATOR CAP
RADIATOR CAP : Inspection INFOID:0000000003801973
CO
• Check valve seat (A) of radiator cap.
- 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 C
top.
- 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. D
- Check that there are no unusualness in the opening and closing
conditions of negative-pressure valve.
E
JPBIA1961ZZ

• Check radiator cap relief pressure. F

Standard and limit : Refer to CO-50, "Radiator".

- When connecting radiator cap to the radiator cap tester (commer- G
cial service tool) and the radiator cap tester adapter (commercial
service tool) (A), apply engine coolant to the cap seal surface.
H

JPBIA0109ZZ
I

• Replace radiator cap if there is an unusualness related to the above three.

CAUTION: J
When installing radiator cap, thoroughly wipe out the radiator pipe (upper) filler neck to remove any
waxy residue or foreign material.
RADIATOR K

RADIATOR : Inspection INFOID:0000000003801974

L
Check radiator for mud or clogging. If necessary, clean radiator as follows:
CAUTION:
• Be careful not to bend or damage radiator fins.
• When radiator is cleaned without removal, remove all surrounding parts such as radiator cooling fan M
assembly and horns. Then tape harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward.
2. Apply water again to all radiator core surfaces once per minute. N
3. Stop washing if any stains no longer flow out from radiator.
4. Blow air into the back side of radiator core vertically downward.
• Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2, 71 psi) and keep distance more than 30 cm O
(11.81 in).
5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.
P

Revision: 2008 December CO-35 J32

 RADIATOR
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]

ON-VEHICLE REPAIR
RADIATOR
Exploded View INFOID:0000000003801975

JPBIA2200GB

1. Reservoir tank cap 2. Reservoir tank 3. Clamp

4. Reservoir tank hose 5. Radiator cap 6. Radiator cap adapter
7. Radiator pipe (upper) 8. Clamp 9. Radiator hose (upper)
10. Radiator hose (upper) 11. O-ring 12. Drain plug
13. Water drain hose 14. Mounting rubber (upper) 15. Radiator upper clip
16. Radiator 17. Mounting rubber (lower) 18. Radiator pipe (lower)
19. Radiator hose (lower) 20. Clamp 21. CVT fluid cooler hose
22. CVT fluid cooler hose 23. Grommet 24. Cooling fan assembly
25. Radiator hose (lower)
A. To water outlet B. To transaxle assembly C. To water inlet
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000003801976

REMOVAL

Revision: 2008 December CO-36 J32

 RADIATOR
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
WARNING:
Never remove radiator cap when engine is hot. Serious burns could occur from high-pressure engine A
coolant escaping from radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter of a turn to
release built-up pressure. Carefully remove radiator cap by turning it all the way.
1. Remove the following parts: CO
• Engine under cover.
• Air duct (inlet): Refer to EM-150, "Exploded View".
• Horn: Refer to HRN-6, "Exploded View".
• Hood lock: Refer to DLK-250, "Exploded View" (WITH INTELLIGENT KEY SYSTEM) or DLK-441, C
"Exploded View" (WITHOUT INTELLIGENT KEY SYSTEM).
2. Drain engine coolant from radiator. Refer to CO-32, "Draining".
CAUTION: D
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.
3. Disconnect reservoir tank hose from radiator pipe (upper). E
4. Disconnect CVT fluid cooler hoses from radiator.
• Install blind plug to avoid leakage of CVT fluid.
5. Disconnect Low-pressure flexible hose from lower pressure pipe, and then move it to aside. Refer to HA- F
105, "Exploded View".
6. Remove radiator cap adapter and each radiator hoses (upper) and radiator pipe (upper) assembly.
CAUTION: G
Be careful not to allow engine coolant to contact drive belt.
7. Disconnect radiator hose (lower) from radiator.
8. Remove condenser. Refer to HA-113, "Exploded View". H
CAUTION:
Be careful not to damage condenser core.
9. Remove each radiator upper clips (2) by pulling the tabs (A) out- I
side to release the lock (B) and then remove each mounting rub-
bers (upper) (1).

C : Mounting pin J
: Vehicle front

CAUTION: K
Never pull the tabs outside excessively to prevent it from
damping.
JPBIA1689ZZ L
10. Lift up and remove radiator from front of radiator core support.
CAUTION:
Be careful not to damage or scratch on radiator core. M

INSTALLATION
Note the following, and install in the reverse order of removal.
N
Radiator Upper Clip
Install each radiator upper clips on radiator core connection as follows:
1. Install each mounting rubbers (upper) (1) on mounting pins (A) O
of radiator.

: Vehicle front P
2. Align each radiator upper clips (2) with radiator core connection
(B), then insert each radiator upper clips straight into radiator
core connections until a click is heard.
3. After connecting each radiator upper clips, use the following
method to check it is fully connected.
• Visually confirm that each radiator upper clips are connected JPBIA1690ZZ
to radiator core connections.

Revision: 2008 December CO-37 J32

 RADIATOR
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
• Move each radiator upper clips and the radiator forward and backward to check they are securely con-
nected.
Inspection INFOID:0000000003801977

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). Refer to CO-32, "Inspection".
• Start and warm up the engine. Visually check that there is no leakage of engine coolant and CVT fluid.

Revision: 2008 December CO-38 J32

 COOLING FAN
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
COOLING FAN
A
Exploded View INFOID:0000000003801978

CO

I
JPBIA1687GB

1. Fan motor (LH) 2. Fan motor (RH) 3. Fan shroud J

4. Mounting rubber 5. Cooling fan (RH) 6. Cooling fan (LH)
A. Apply on fan motor shaft
: Vehicle front K
: Apply high strength thread locking sealant or equivalent.

Refer to GI-4, "Components" for symbols not described on the above.

L
Removal and Installation INFOID:0000000003801979

REMOVAL M
1. Remove the following parts.
• Engine under cover
• Air duct (inlet): Refer to EM-150, "Exploded View". N
• Oil level gauge: Refer to EM-221, "Exploded View".
• Battery and battery tray: Refer to PG-144, "Exploded View".
2. Drain engine coolant from radiator. Refer to CO-32, "Draining". O
CAUTION:
• Perform this step engine is cold.
• Never spill engine coolant on drive belt.
P
3. Remove radiator cap adapter and radiator hoses (upper) and radiator pipe (upper) assembly. Refer to
CO-36, "Exploded View".
4. Disconnect harness connector from fan motors (RH and LH), and move harness to aside.
5. Disconnect harness connector from crash zone sensor, and move harness to aside. Refer to SR-18,
"Exploded View".
6. Remove battery tray bracket mounting bolts, and move battery tray bracket to aside.
7. Remove cooling fan assembly.

Revision: 2008 December CO-39 J32

 COOLING FAN
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
CAUTION:
Be careful not to damage or scratch on radiator core.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Only use genuine parts for cooling fan mounting bolt and observe the specified torque (to prevent
radiator from being damaged).
NOTE:
Cooling fans are controlled by ECM. For details, refer to EC-706, "System Diagram" (TYPE 1) or EC-1122,
"System Diagram" (TYPE2).
Disassembly and Assembly INFOID:0000000003801980

DISASSEMBLY
1. Remove cooling fan mounting nuts, and then remove the cooling fans (RH and LH).
2. Remove fan motors (RH and LH).
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
CAUTION:
RH and LH cooling fans are different. Be careful not to misassemble them.
• Install each fan in the following position.

Right side : 11 blades

Left side : 9 blades
• Secure the harness tightly to the fan shroud to prevent the fan rotation area from being loose.
• Apply high thread locking sealant on for motor shaft.
Inspection INFOID:0000000003801981

INSPECTION AFTER DISASSEMBLY

Cooling Fan
Inspect cooling fan for crack or unusual bend.
• If anything is found, replace cooling fan.

Revision: 2008 December CO-40 J32

 WATER PUMP
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
WATER PUMP
A
Exploded View INFOID:0000000003801982

CO

G
JPBIA2460GB

Valve timing control cover gasket

1. Timing chain tensioner (primary) 2. 3. Valve timing control cover (bank 1) H
(bank 1)
4. Water drain plug (front) 5. Water pump cover 6. O-ring
7. O-ring 8. Water pump
A. Apply engine coolant B. Identify with white paint mark I
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000003801983 J

CAUTION:
• When removing water pump assembly, be careful not to get engine coolant on drive belt.
• Water pump cannot be disassembled and should be replaced as a unit. K
• After installing water pump, connect hose, and clamp securely, then check for leakage using the
radiator cap tester (commercial service tool) and the radiator cap tester adapter (commercial service
tool). L
REMOVAL
1. Remove the following parts.
• Air duct (inlet): Refer to EM-150, "Exploded View". M
• Engine cover: Refer to EM-148, "Exploded View".
• Engine under cover
• Front road wheel and tire N
• Splash guard (RH): Refer to EXT-24, "FENDER PROTECTOR : Exploded View".
2. Drain engine coolant from radiator. Refer to CO-32, "Draining".
CAUTION: O
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.
3. Remove drive belt. Refer to EM-136, "Removal and Installation".
P
4. Remove idler pulleys. Refer to EM-149, "Exploded View".
5. Remove reservoir tank of radiator. Refer to CO-36, "Exploded View".
6. Remove reservoir tank of power steering oil pump with piping connected, and move it to aside. Refer to
ST-37, "Exploded View".
7. Support oil pan (lower) bottom with transmission jack.
8. Remove engine mounting insulator (RH), engine mounting bracket (RH), and upper torque rod. Refer to
EM-192, "Exploded View".

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 WATER PUMP
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
9. Remove water drain plug (front) on water pump side of cylinder block to drain engine coolant from engine
inside.
10. Remove valve timing control cover (bank 1) and water pump cover from front timing chain case.
• Use the seal cutter [SST: KV10111100] to cut liquid gasket for removal.
11. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt (1).
CAUTION:
Be careful not to drop mounting bolt inside timing chain
case.
b. Loosen upper mounting bolt (2) slowly, and then turn chain ten-
sioner (primary) (3) on the mounting bolt so that plunger (4) is
fully expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body
of timing chain tensioner (primary).
JPBIA0085ZZ

c. Turn crankshaft pulley clockwise so that timing chain on the tim-

ing chain tensioner (primary) side is loose.

PBIC4820E

d. Remove upper mounting bolt, and then remove timing chain ten-
sioner (primary).
CAUTION:
Be careful not to drop mounting bolt inside timing chain
case.

PBIC3576E

12. Remove water pump as follows:

a. Remove three water pump mounting bolts. Secure a gap
between water pump gear and timing chain, by turning crank-
shaft pulley counterclockwise until timing chain looseness on
water pump sprocket becomes maximum.

PBIC1193E

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 WATER PUMP
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
b. Screw M8 bolts [pitch: 1.25 mm (0.0492 in) length: approxi-
mately 50 mm (1.97 in)] into water pumps upper and lower A
mounting bolt holes until they reach timing chain case. Then,
alternately tighten each bolt for a half turn, and pull out water
pump.
CO
CAUTION:
• Pull straight out while preventing vane from contacting
socket in installation area.
• Remove water pump without causing sprocket to contact C
timing chain.
c. Remove M8 bolts and O-rings from water pump. JLC357B
CAUTION: D
Never disassemble water pump.
INSTALLATION
1. Install new O-rings to water pump. E
• Apply engine oil and engine coolant to O-rings as shown in the
figure.
• Locate O-ring with white paint mark to engine front side. F

H
PBIC1397E

2. Install water pump. I

CAUTION:
Never allow cylinder block to nip O-rings when installing
water pump.
J
• Check that timing chain and water pump sprocket are
engaged.
• Insert water pump by tightening mounting bolts alternately and
evenly. K

SLC031B L

3. Install timing chain tensioner (primary) as follows:

a. Turn crankshaft pulley clockwise so that timing chain on the tim- M
ing chain tensioner (primary) side is loose.

PBIC4820E P

Revision: 2008 December CO-43 J32

 WATER PUMP
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
b. Pull plunger stopper tab (A) up (or turn lever downward) so as to
remove plunger stopper tab from the ratchet of plunger (D).
NOTE:
Plunger stopper tab and lever (C) are synchronized.
c. Push plunger into the inside of tensioner body.
d. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet.
e. To secure lever, insert stopper pin (E) through hole of lever into
tensioner body hole (B).
• The lever parts and the tab are synchronized. Therefore, the
plunger will be secured under this condition. JPBIA0118ZZ

NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
f. Install timing chain tensioner (primary).
• Remove dust and foreign material completely from backside of timing chain tensioner (primary) and
from installation area of rear timing chain case.

g. Remove stopper pin (A).

JPBIA1774ZZ

h. Check again that timing chain and water pump sprocket are engaged.
4. Install valve timing control cover (bank 1) and water pump cover as follows:
a. Before installing, remove all traces of old liquid gasket from mating surface of water pump cover using
scraper. Also remove traces of old liquid gasket from the mating surface of front timing chain case.

b. Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) to mating surface of water pump cover
(1).

a : φ2.3 - 3.3 mm (0.091 - 0.130 in)

Use Genuine Liquid Gasket or equivalent.
CAUTION:
Attaching should be done within 5 minutes after coating.
c. Tighten mounting bolts.
JPBIA1722ZZ

5. Install water drain plug (front) on water pump side of cylinder block.
• Apply liquid gasket to the thread of water drain plug (front).
Use Genuine Liquid Gasket or equivalent.
6. Install in the reverse order of removal after this step.
• After starting engine, let idle for three minutes, then rev engine up to 3,000 rpm under no load to
purge air from the high-pressure chamber of chain tensioner. Engine may produce a rattling
noise. This indicates that air still remains in the chamber and is not a matter of concern.
Inspection INFOID:0000000003801984

INSPECTION AFTER REMOVAL

• Check for badly rusted or corroded water pump body assembly.

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 WATER PUMP
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
• Check for rough operation due to excessive end play.
• If anything is found, replace water pump. A

CO

SLC943A

D
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). Refer to CO-32, "Inspection".
• Start and warm up the engine. Visually check that there is no leakage of engine coolant. E

Revision: 2008 December CO-45 J32

 WATER INLET AND THERMOSTAT ASSEMBLY
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
WATER INLET AND THERMOSTAT ASSEMBLY
Exploded View INFOID:0000000003801985

JPBIA1688GB

1. Gasket 2. Water inlet and thermostat assembly 3. Clamp

4. Radiator hose (lower)
A. To radiator
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000003801986

REMOVAL
1. Drain engine coolant from radiator drain plug at the bottom of radiator, and from water drain plug at the
front of cylinder block. Refer to CO-32, "Draining" and EM-235, "Disassembly and Assembly".
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.
2. Remove reservoir tank of radiator, and move it aside. Refer to CO-36, "Exploded View".
3. Remove intake valve timing control solenoid valve (bank 2). Refer toEM-177, "Exploded View".
4. Disconnect radiator hose (lower) from water inlet and thermostat assembly.
5. Remove water inlet and thermostat assembly (1).

A : Never loosen these screw

CAUTION:
Never disassemble water inlet and thermostat assembly.
Replace them as a unit, if necessary.

JPBIA0261ZZ

INSTALLATION
Note the following, and install in the reverse order of removal.
• Be careful not to spill engine coolant over engine room. Use rag to absorb engine coolant.

Revision: 2008 December CO-46 J32

 WATER INLET AND THERMOSTAT ASSEMBLY
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
Inspection INFOID:0000000003801987

A
INSPECTION AFTER REMOVAL
1. Check valve seating condition at ordinary room temperatures. It should seat tightly.
CO
2. Check valve operation.

Thermostat (Standard) : Refer to CO-50, "Thermostat".

C
• If the malfunctioning condition, when valve seating at ordinary
room temperature, or measured values are out of the standard,
replace water inlet and thermostat assembly. D

E
SLC949A

INSPECTION AFTER INSTALLATION

• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the F
radiator cap tester (commercial service tool). Refer to CO-32, "Inspection".
• Start and warm up the engine. Visually check that there is no leakage of engine coolant.
G

Revision: 2008 December CO-47 J32

 WATER OUTLET AND WATER PIPING
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
WATER OUTLET AND WATER PIPING
Exploded View INFOID:0000000003801988

JPBIA1691GB

1. Heater hose 2. Clamp 3. Water hose

4. Clamp 5. Water outlet 6. Gasket
7. Gasket 8. Water connector 9. O-ring
10. Water bypass pipe 11. Clamp 12. Water hose
13. Heater pipe 14. Water hose 15. Heater hose
16. Engine coolant temperature sensor 17. Clamp 18. Radiator hose (upper)
A. To heater core B. To electric throttle control actuator C. To oil cooler
D. To radiator
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000003801989

REMOVAL
1. Remove air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor, and air duct
assembly. Refer to EM-150, "Exploded View".
2. Remove engine cover. Refer to EM-148, "Exploded View".
3. Drain engine coolant from radiator drain plug at the bottom of radiator, and from water drain plug at the
front of cylinder block. Refer to CO-32, "Draining" and EM-235, "Disassembly and Assembly".
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.
4. Remove battery and battery tray. Refer to PG-144, "Exploded View".

Revision: 2008 December CO-48 J32

 WATER OUTLET AND WATER PIPING
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
5. Remove CVT fluid charging pipe and CVT fluid level gauge. Refer to TM-356, "Exploded View" (VQ25DE)
or TM-173, "Exploded View" (VQ35DE). A
6. Move CVT control cable aside. Refer to TM-340, "Exploded View" (VQ25DE) or TM-162, "Exploded View"
(VQ35DE).
7. Remove vacuum tube (front) mounting bolt from water outlet. Refer to EM-192, "Exploded View". CO
8. Remove radiator hose (upper) from water outlet.
9. Remove water hoses and heater hoses.
10. Disconnect harness connectors, and move harness to aside. C
11. Remove engine coolant temperature sensor if necessary.
CAUTION:
Be careful not to damage engine coolant temperature sensor. D
12. Remove water outlet, heater pipe, water bypass pipe, and water connector.
INSTALLATION E
Note the following, and install in the reverse order of removal.
• Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.
• When inserting water bypass pipe and heater pipe into water connector, apply neutral detergent to O-ring.
F
Inspection INFOID:0000000003801990

INSPECTION AFTER INSTALLATION G

• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-32, "Inspection".
• Start and warm up the engine. Visually check that there is no leakage of engine coolant.
H

Revision: 2008 December CO-49 J32

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [VQ25DE, VQ35DE]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)
Periodical Maintenance Specification INFOID:0000000003801991

ENGINE COOLANT CAPACITY (APPROXIMATE)

Unit: (lmp qt)

Engine coolant capacity (With reservoir tank at “MAX” level) 9.1 (8)
Reservoir tank 0.8 (3/4)

Radiator INFOID:0000000003801992

Unit: kPa (bar, kg/cm2, psi)

Standard 122.3 - 151.7 (1.2 - 1.5, 1.2 - 1.5, 17.7 - 22.0)

Cap relief pressure
Limit 108 (1.1, 1.1, 15.6)
Leakage test pressure 157 (1.57, 1.6, 22.8)

Thermostat INFOID:0000000003801993

Standard
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Maximum valve lift 8.6 mm/95°C (0.339 in/203°F)
Valve closing temperature 77°C (171°F)

Revision: 2008 December CO-50 J32