Service Manual
Contents
1. NX CD Power steering pump drive belt 2 V ribbed belt 8 Water pump pulley 4 Water pump Assy 5 Water pump gasket JCO00018 00016 REMOVAL 1 Drain the engine coolant Refer to page CO 3 2 Remove the drive belt Refer to the CH section 3 Remove the power steering pump drive belt J102 only 1 Loosen the bolts and 8 2 Remove the power steering pump drive belt by mov ing the power steering pump 4 Remove the water pump pulley while preventing it from turning using a screwdriver or the like as indicated in the right figure 5 Hemove the water pump Assy and gasket JCO00020 00018 CO 7 INSPECTION 1 Check the water pump pulley for damage or deformation Replace the water pump pulley if it exhibits damage or de formation Visually inspect the water pump rotor for damage or defor mation Replace the water pump if the water pump rotor exhibits damage or deformation Ensure that the water pump rotates smoothly by hand Replace the water pump if it will not rotate smoothly Visually inspect the water pump pulley seat for damage or deformation Replace the water pump if it exhibits damage or deforma tion INSTALLATION 1 Install the water pump assembly and gasket Tightening Torque 7 2 10 8 Install the water pump pulley while preventing it from turn ing using a screwdriver or the like as indicated in the right fig2. Reserve tank capacity Thermostat Valve lift Relief valve opening pressure 108 15 kPa 1 1 0 15 kg cm Radiator cap YCO00064 00000 TIGHTENING TORQUE Components N m kgf m Remarks Water pump x Cylinder block 7 2 10 8 0 72 1 08 Water pump x Water pump pulley 8 1 15 0 0 81 1 50 Water inlet x Cylinder head 7 2 10 8 0 72 1 08 M101 M201 J102 Water inlet pipe x Cylinder block 6 3 11 7 0 63 1 17 5221 only Water outlet housing x Water outlet 11 2 16 8 1 12 1 68 5221 only Fan motor x Fan shroud 1 8 3 3 0 18 0 33 2 7 5 0 0 27 0 50 Fan motor x Fan 4 9 7 4 0 49 0 74 Fan shroud x Radiator 6 4 9 6 0 64 0 96 M101 M201 Fan shroud x Radiator 5 3 9 7 0 53 0 97 221 J102 Coolant reserve tank x Fan shroud 6 4 9 6 0 64 0 96 Radiator bracket x Support upper member 6 4 9 6 0 64 0 96 5221 only YCOO00065 00000 TO INDEX TO NEXT SECTION
3. TO INDEX COOLING SYSTEM CHECK amp CHANGE OF ENGINE REMOVAL ssassuss sas sasana sangan aa gga co 9 COOLANT inizi inen ara ar add CO 2 INSPECTION 10 PRECAUTIONS qsuxnds xxksisskxic ina Eua co 2 INSTALLATION CO 10 1 CHECK OF ENGINE COOLANT RADIATOR CO 11 6 87 M 1 dee CO 2 COMPONENTS 11 CHECK OF ENGINE COOLANT RADIATOR S221 CO 11 1 LEVEL Sessi sesanan sapan aaa anna aaa aa sanan co 2 COMPONENTS S221 CO 11 1 CHANGE OF ENGINE REMOVAL CO 11 1 eq mine co 2 INSTALLATION CO 12 WATER PUMP 355 256 i CO 6 CLEANING OF RADIATOR CO 13 COMPONENTS CO 6 INSPECTION OF RADIATOR CO 13 REMOVAL CO 6 ELECTRIC COOLING FAN 14 INSPEC TION aas sina nanses gana ncn CO 7 IN VEHICLE INSPECTION CO 14 INSTALLATION CO 7 SPECIFICATIONS CO 15 THERMOSTAT CO 9 TIGHTENING TORQUE CO 15 COMPONENTS kk aa aa ai aaa aaa Karda MA aa KANAN CO 9 JCO00001 00000 CO 2 CHECK amp CHANGE OF ENGINE COOLANT PRECAUTIONS WARNING e the coolant gets to the vehicle body immediately flush away the coolant using water Never open the radiator cap when the engine is still hot Failure to observe this caution will cause you to get scalded e The inside of the radiator is under a pressurized condi tion when the cooling w
4. with coolant in accordance with the instructions of the manufacturer of the antifreeze solution CAUTION e Use a reliable brand of ethylene glycol base antifreeze solution Coolant Capacity W heater W O reserve tank MT 5 802 AT 5 722 Reserve Tank Capacity 0 95 2 9 Tighten the cock when the coolant starts to overflow from the air bleeding valve 10 Tighten the cock when the coolant starts to overflow from the air bleeding valve 11 Tighten the radiator cap when the coolant starts to overflow from the radiator Also add the coolant to the reserve tank 12 Warm up the engine until the cooing fan operates twice and then stop the engine 13 After the engine has cooled down fill the radiator with the coolant and add the coolant up to the full level of the reserve tank NOTE If no coolant overflows from the air bleeding valves or or no coolant overflows from both valves and B steps 9 and 10 above tighten the cocks of the air bleed ing valves after coolant overflows from the radiator 221 Series 1 Tighten the drain plug of the radiator Fill the radiator with water CAUTION e As regards water to be used as cooling water use soft water which does not contain salts of minerals calci um magnesium and so forth NOTE e The operations described in steps 1 through 6 are to completely expel any deteriorated coolant remaining in the cooling system 2 Tight
5. Drain the coolant by loosing the radiator drain plug J102 Series 1 Remove the radiator cap 2 Loosen and remove the cocks white of the air bleed ing valves and B 3 Drain the coolant by loosing the radiator drain plug S221 Series 1 Remove the radiator cap 2 Drain the coolant by loosening the radiator drain plug 3 Loosen the bleeder plug located at the top of the en gine water outlet housing 2 FILL ENGINE COOLANT M101 amp M201 Series 1 Tighten the drain plug of the radiator Fill the radiator with water CAUTION As regards water to be used as cooling water use soft water which does not contain salts of minerals calci um magnesium and so forth NOTE The operations described in steps 1 through 5 are to completely expel any deteriorated coolant remaining in the cooling system 2 Tighten the radiator cap 3 Start the engine and keep warming up the engine and then stop the engine and allow it to cool down 4 Drain the water Refer to page CO 3 5 Repeat the steps 1 through 4 two to three times Radiator cap pem Front of vehicle Drain plug YCOO00006 00003 YCOO00009 00006 YCO00010 00000 CO 4 Revision 2 6 Tighten the drain plug of the radiator Fill the radiator E with coolant in accordance with the instructions of the LO Engine manufacturer of the antifreeze solution coolant CAUTION e Use a reliable brand of ethylene
6. More than 8 5 mm 5221 Series Under the condition described in the step 1 heat the water to 100 C At this time ensure that the valve lift is the specified value or more Specified Value More than 8 0 mm CAUTION Be very careful not to get scalded for the heated ther mostat will be very hot M101 M201 amp J102 Series More than 8 5 mm 1 S221 Series More than 8 0 mm YCOO00034 00026 YCOO00035 00027 YCOO00037 00029 YCOO00000 00030 Revision 2 INSTALLATION M101 M201 amp J102 Series 1 Install the thermostat to the water inlet NOTE Be sure to assemble the thermostat at the position indi cated in the right figure 2 Install the water inlet to the cylinder head Tightening Torque 7 2 10 8 3 Connect the radiator thermo control switch connector Only for EU spec 4 Fill the engine coolant Refer to page CO 3 5 Start the engine Ensure that no water leakage is present 5221 Series 1 Assemble the thermostat to the water outlet with its jiggle pin facing upward 2 Install the water outlet to the water outlet housing Tightening Torque 11 2 16 8 3 Install the water outlet housing to the cylinder head Tightening Torque 16 0 24 0 4 Fill the engine coolant Refer to page CO 5 5 Start the engine Ensure that no water leakage is present Jiggle pin YCO00076 00054 Protruding section Cutout section YCOO
7. glycol base antifreeze solution Coolant Capacity 3 8 2 W heater W O reserve tank Reserve Tank Capacity Full 0 45 2 Low 0 252 1 1 00007 7 Tighten the radiator cap Also add the coolant to the reserve tank 8 Warm up the engine until the cooling fan operates twice and then stop the engine 9 After the engine has cooled down fill the radiator with coolant and add the coolant up to the full level of the reserve tank YCOO00012 00000 J102 Series 1 Tighten the drain plug of the radiator Fill the radiator with water CAUTION e As regards water to be used as cooling water use soft water which does not contain salts of minerals calci um magnesium and so forth NOTE The operations described in steps 1 through 7 are to completely expel any deteriorated coolant remaining in the cooling system 2 Tighten the cock W when the water starts to overflow from the air bleeding valve A 3 Tighten the cock B when the water starts to overflow from the air bleeding valve B 4 Tighten the radiator cap when the water starts to over flow from the radiator 5 Start the engine and keep warming up the engine and then stop the engine and allow it to cool down 6 Drain the water Refer to page CO 3 7 Repeat the steps 1 through 6 two to three times YCOO00066 00048 Revision 1 CO 5 8 Tighten the drain plug of the radiator Fill the radiator
8. no external leakage is found check the heater core cylinder block cylinder head and throttle body for evi dence of leakage Check the hoses for deterioration cracks bulge or damage Replace the defective part s if necessary 4 Remove the radiator cap tester from the radiator WARNING Never open the radiator cap and or drain cap when the coolant is still hot Failure to observe this caution will cause you to get scalded sCO00053 00037 Seal surfaces sCO00054 00038 sCO00056 00040 sCO00057 00000 CO 14 ELECTRIC COOLING FAN IN VEHICLE INSPECTION 1 If the fan motor is rotating when the coolant temperature is below 80 C and the ignition switch is at the off position check the RAD FAN relay and the wiring harness for short 1 Disconnect the RAD FAN relay from the relay Block 2 If the fan motor stops check the RAD FAN relay 3 If the fan motor is rotating check the wiring harness for short 2 Turn on the ignition key switch Ensure that the fan is not rotating when the coolant is cold below 80 C If the fan motor is rotating check the engine coolant temperature sensor and radiator thermo control switch EC spec 3 Warm the engine until the radiator coolant temperature rises above 100 C Ensure that the fan motor is rotating If the fan motor is not rotating check the RAD FAN relay wiring harness radiator fan motor fuse radiator fan motor water temperature sensor and rad
9. undercover Drain the engine coolant Refer to page CO 3 Remove the front bumper Remove the condenser air conditioner NOTE Bevery careful not to disconnect the pipes that have been connected to the condenser On automatic transmission vehicles disconnect the oil cooler hose Disconnect the radiator inlet hose and radiator outlet hose at the radiator side Remove the radiator bracket and coupler of the fan motor Remove the fan motor assembly and radiator assembly as a set CO 1 2 Revision 2 S221 Series WARNING e Never remove the radiator cap and drain plug when the engine coolant is still hot 1 Disconnect the cable from the negative terminal of the battery NOTE It should be noted that the memories of diagnosis results radio etc will be erased at same time when the cable is disconnected from the negative terminal of the battery 2 Drain the coolant 3 Remove the front grille and front bumper 4 Remove the hood lock 5 Disconnect the oil cooler hose A T 6 Disconnect the radiator hoses No 1 and No 2 7 Remove the radiator bracket 8 Remove the radiator support upper member 9 Remove the radiator assembly 10 Remove the fan motor assembly with shroud NOTE e When the radiator assembly is removed be sure to lift the radiator assembly while pulling the con denser for air conditioner toward your side Do not disconnect the pipes of the condenser for air conditioner Y
10. 0 00025 REMOVAL M101 M201 amp J102 Series Drain the engine coolant Refer to CO 3 2 Disconnect the radiator thermo control switch connector Only for EU spec 3 Remove the water inlet from the cylinder head 4 Remove the thermostat from the cylinder head S221 Series 1 Drain the engine coolant Refer to CO 3 2 Remove the water outlet from the cylinder head 3 Remove the thermostat from the cylinder head 65033 60060 CO 10 Revision 2 INSPECTION Ensure that the thermostat valve is closed at room temper ature of 20 C and the spring has no play Replace the thermostat if the valve is open or the spring has a play 1 Check the rubber grommet of the thermostat for damage or crack Replace the thermostat if the rubber grommet exhibits damage or crack Check of thermostat valve opening temperature 1 Immerse the thermostat in water as indicated in the right figure Heat the water gradually Ensure that the temperature at which the valve begins to open con forms to the specified value Specified Valve Opening Temperature M101 M201 amp J102 Series 80 x 2 5221 Series 88 1 5 If the temperature fails to conform to the specification replace the thermostat with a new one M101 M201 amp J102 Series Under the condition described in the step 1 heat the water to 93 C At this time ensure that the valve lift is the specified value or more Specified Value
11. 00042 0003 Revision 2 CO 1 1 RADIATOR COMPONENTS M101 amp M201 Series Tightening torque Unit CD Radiator reserve tank 4 Radiator bracket 2 Radiator inlet hose 5 Fan motor assy 3 Radiator outlet hose 6 Radiator assy YCO00043 00035 J102 Series Tightening torque Unit N WSS CD Radiator reserve tank 4 Radiator bracket 2 Radiator inlet hose 5 Fan motor assy Q Radiator outlet hose 6 Radiator assy YCOO00000 00056 CO 1 1 1 Revision 2 RADIATOR 5221 5221 5221 Series Tightening torque Unit N m CD Radiator fan motor 2 Radiator reserve tank 3 Radiator No 1 hose 4 Radiator No 2 hose 5 Radiator bracket 6 Radiator support member 7 Radiator assy Fan motor assy with shroud YCOO00046 00036 REMOVAL M101 M201 amp J102 Series 9 B OIN WARNING e Never remove the radiator cap and drain plug when the engine coolant is still hot Disconnect the cable from the negative terminal of the battery NOTE e t should be noted that the diagnosis results and memory the radio will be erased when the cable is disconnected from the negative terminal of the battery Remove the engine
12. COO00047 00000 INSTALLATION M101 M201 amp J102 Series Install the fan motor assembly and radiator assembly as a set Install the radiator bracket Install the coupler of the fan motor Connect the radiator inlet hose and radiator outlet hose to the radiator On automatic transmission vehicles connect the automatic transmission oil cooler hose to the radiator Refer to the A T section Install the condenser air conditioner Fill engine coolant Refer to page CO 3 Install the front bumper Install the engine undercover Connect the cable to the negative terminal of the battery Check the radiator for leakage o PRON tOO MND ok YCOO00049 00000 Revision 1 CO 1 2 1 5221 Series Install the fan motor assembly and radiator assembly as a set Install the radiator Install the radiator bracket Install the coupler of the fan motor Connect the radiator No 1 hose and radiator 2 hose to the radiator On automatic transmission vehicles connect the automatic transmission oil cooler hose to the radiator Refer to the A T section Install the hood lock Install the front grille and bumper Fill engine coolant Refer to page CO 3 Connect the cable to the negative terminal of the battery Check the radiator for leakage DUREN gt ok O 9 097 sCO00052 00000 Revision 1 CO 13 CLEANING OF RADIATOR Using water or steam cleaner remove mud and dirt from the radiato
13. ater is hot Therefore if the ra diator cap should be removed the cooling water will blow off possibly causing injuries such as scald CAUTION e Here the coolant refers to the mixture of water and an tifreeze of a reliable brand that has been mixed in ac cordance with the instructions of the antifreeze manu facturer CHECK OF ENGINE COOLANT QUALITY There should be no excessive deposits of rust or water scales around the radiator cap or the radiator filler hole Also the coolant should be free of oil Change the coolant if it is excessively dirty CHECK OF ENGINE COOLANT LEVEL Check to see if the coolant level is between the L and F lines of the reserve tank If the coolant level is near the low level or below the low level add the coolant up to the full level NOTE f no coolant is present in the reserve tank or the coolant level is very low check for water leakage using a radiator cap tester Refer to the page CO 13 CHANGE OF ENGINE COOLANT CAUTION sure to perform the coolant change after the engine has cooled down Furthermore with regard to the engine coolant chang ing procedure be sure to refer to the engine service in formation label affixed to the body JCO00002 00000 JCO00003 00001 JCO00004 00000 Radiator cap yt Front of vehicle Drain plug JCO00005 00003 Revision 2 CO 3 1 DRAIN ENGINE COOLANT M101 amp M201 Series 1 Remove the radiator cap 2
14. en the bleeder plug when the water starts to over flow from the bleeder plug 3 Tighten the radiator cap when the water starts to over flow from the radiator sCO00067 00000 sCO00068 00049 sCO00069 00000 5 0007 1 00051 5 1 Revision 1 4 Start the engine and keep warming up the engine and then stop the engine and allow it to cool down 5 Drain the water Refer to page CO 3 6 Repeat the steps 1 through 5 two to three times sCO00072 00000 7 Tighten the drain plug of the radiator Fill the radiator with coolant in accordance with the instructions of the manufacturer of the antifreeze solution CAUTION e Use a reliable brand of ethylene glycol base antifreeze solution Coolant Capacity W heater W O reserve tank MT 6 50 2 AT 6 702 Reserve Tank Capacity 0 7 2 8 Tighten the bleeder plug when the coolant starts to overflow from the bleeder plug 9 Tighten the radiator cap when the coolant starts to overflow from the radiator Also add the coolant to the reserve tank 5 00074 00053 10 Warm up the engine until the cooing fan operates twice and then stop the engine 11 After the engine has cooled down fill the radiator with the coolant and add the coolant up to the full level of the reserve tank 5 000075 00000 CO 6 WATER PUMP COMPONENTS Tightening torque Non reusable parts Unit N m
15. iator thermo control switch EC spec Radiator fan motor check 1 Disconnect the connector of the radiator fan motor 2 Check resistance between the terminals of the radiator fan motor Specified Value Approx 1 0 Q Radiator fan motor relay check The radiator fan motor relay employs the same relay as the starter relay Therefore for the unit inspection refer to the ST section Engine coolant temperature sensor check Refer to the EF section Radiator thermo control switch check EC specifications only 1 Ensure that continuity exists between the terminals when the water temperature is 94 C or above If there is no continuity replace the radiator thermo control Switch 2 Allow the water temperature to drop When the tempera ture becomes 83 or below ensure that no continuity ex ists between the terminals If there is continuity replace the radiator thermo control switch RAD FAN Rela ud JCO00048 00046 JCO00049 00000 JCO00050 00047 JCO00051 00048 JCO00052 00049 Revision 2 CO 1 5 SPECIFICATIONS 3 80 5 80 Coolant capacity 6 50 w heater W O reserve tank 3 80 5 72 6 70 0 45 0 95 0 70 0 25 LOW 0 18 0 20 Valve opening M201 J102 80 0 2 0 C temperature 88 0 1 5 M201 J102 8 5 mm or more at 93 C 8 0 mm or more at 100 C
16. r core CAUTION When using high pressure type cleaner be very careful not to deform the radiator core fins Keep a distance of more than 40 50 cm between the radiator core and the cleaner nozzle when the cleaner nozzle pressure is 2 9 4 9 MPa e Also the injection angle of pressurized water should be right angles to the radiator Failure to observe this caution will cause the radiator fins to be deformed INSPECTION OF RADIATOR 1 Check of radiator cap 1 Check the seal packing of the radiator cap for dam age Replace the radiator cap with a new one if any dam age exists 2 Lift the valve at the vacuum side with your fingers Ensure that the valve is functioning properly Replace the radiator cap with a new one if the valve fails to function 3 Check the radiator cap by means of a radiator cap tester to see if the relief valve opens at a pressure of 108 15 kPa If the radiator cap fails to conform to the specification replace the radiator cap CAUTION Never open the radiator cap when the engine is still hot e Failure to observe this caution will cause you to get scalded 2 Check of cooling system for leakage 1 Fill the radiator with coolant Attach a radiator cap tester 2 Warm up the engine 3 Apply a pressure of 122 7 kPa to the cooling system by means of the radiator tester If the pressure drops check the hoses radiator water pump and heater for evidence of leakage If
17. ure Tightening Torque 8 1 15 0 N m Install the power steering pump drive belt J102 only 1 Install the power steering pump drive belt between the water pump pulley and the power steering pump pul ley 2 Adjust the tension by moving the power steering pump 3 Tighten the bolts and Tightening Torque 34 4 52 0 JCO00022 00000 JCO00026 00024 CO 8 4 Check the tension of the power steering pump drive Power steering belt pump pulley Measuring Specified Value oe New belt Used belt Belt deflection amount 7 0 9 0 mm 9 0 11 0 mm Belt tension 294 392 196 294 When the belt deflection amount is measured the measurement should be carried out with a force of Water pump pulley 98 N applied between the designated pulleys in the JCO00027 00025 right figure As regards the belt that has been used for more than five minutes it should be adjusted according to the specified value for the used belt 4 Install the drive belt Refer to the CH section TEN 5 Fill engine coolant Refer to page CO 3 LO Engine coolant JCO00028 00026 Revision 2 CO 9 THERMOSTAT COMPONENTS M101 M201 amp J102 Series Tightening torque Unit N m CD Hose 2 Water inlet 9 Thermostat YCOO00032 00024 S221 Series Tightening torque Nem 11 2 16 8 CD Radiator No hose 2 Water outlet 3 Thermostat YCOO0000
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