ENGINE COOLING SYSTEM
Contents
1. BOD Be careful not to bend or damage the radiator fins When radiator is cleaned without removal remove all surrounding parts such as cooling fan radiator shroud and horns Then tape the harness and electrical connectors to prevent water from entering Apply water by hose to the back side of the radiator core vertically downward Apply water again to all radiator core surface once per minute Stop washing if any stains no longer flow out from the radiator Blow air into the back side of radiator core vertically downward e Use compressed air lower than 490 kPa 5 kg cm 71 psi and keep distance more than 30 cm 11 8 in Blow air again into all the radiator core surfaces once per minute until no water sprays out Revision 2004 April CO 17 2003 G35 Sedan RADIATOR ALUMINUM TYPE RADIATOR ALUMINUM TYPE PFP 21460 Disassembly and Assembly assoo02t SEC 214 G Always replace after every disassembly PBIC2539E PREPARATION 1 Attach spacer to tip of radiator plate pliers A special service tool Spacer specification 18 mm 0 71 in wide x 8 5 mm 0 335 in long x 1 5 mm 0 059 in thick KV99103510 Unit mm in SLC655CB 2 Make sure that when radiator plate pliers A special service tool KV99103510 _ are closed dimen sion H is approx 7 6 mm 0 299 in 3 Adjust dimension H with spacer if necessary DISASSEMBLY 1 Remove upper and lower tanks with radiator plate pliers B s2. F M T 8 6 mm 90 C 0 339 in 194 F Radiator aBso0015 Unit kPa kg cm psi EE pressie Standard 78 98 0 8 1 0 11 14 Limit 59 0 6 9 Leakage test pressure 157 1 6 23 Tightening Torque ABso0aJs Unit N m kg m ft lb N m kg m in lb Air relief plug 0 78 1 6 0 08 0 16 7 14 Radiator drain plug 0 78 1 6 0 08 0 16 7 14 Fan shroud A T models 3 8 4 5 0 39 0 45 34 39 A C condenser 5 7 6 5 0 59 0 66 51 57 Reservoir tank 3 8 4 5 0 39 0 45 34 39 Radiator cooling fan assembly M T models 3 8 4 5 0 39 0 45 34 39 Cooling fan crankshaft driven A T models 5 9 9 8 0 6 1 0 53 86 Fan coupling A T models 5 9 9 8 0 6 1 0 53 86 Cooling fan motor driven 2 9 3 9 0 30 0 39 26 34 Fan grille A T models 5 7 6 5 0 58 0 66 51 57 Fan motor 3 9 4 9 0 40 0 49 35 43 Water drain plug front 7 8 11 8 0 8 1 2 69 104 Water pump 8 4 10 8 0 9 1 1 75 95 Water pump cover 9 8 12 8 1 0 1 3 87 113 Chain tensioner cover 9 8 12 8 1 0 1 3 87 113 Chain tensioner 6 9 9 3 0 70 0 94 61 82 Water outlet 21 6 27 4 2 2 2 7 16 20 Thermostat and thermostat housing 8 4 10 8 0 9 1 1 75 95 Engine coolant temperature sensor 19 6 29 4 2 0 2 9 15 21 Revision 2004 April CO 34 2003 G35 Sedan
3. INSPECTION INSPECTION 1 Apply pressure with radiator cap tester adapter special service tool and radiator cap tester commercial service tool Testing pressure JX ard 157 kPa 1 6 kg cm 23 psi WARNING To prevent the risk of hose coming undone while under pressure securely fasten it down with hose clamp CAUTION Attach hose to A T fluid cooler to seal its inlet and outlet A T models sucess 2 Check for leakage by soaking radiator in water container with the testing pressure applied SLC934 Revision 2004 April CO 21 2003 G35 Sedan COOLING FAN COOLING FAN PFP 21140 Removal and Installation Crankshaft Driven Type A T Models aBsooauP SEC 210 Front mark F i INANA Fan pulley bracket A e ie Refer to TIMING hy 5 9 9 8 0 6 1 0 53 86 De Fan pulley CHAIN in EM section Else s Le sd K RO nea 86 Engine front o Nem kg m in lb Cooling fan PBIC1692E REMOVAL 1 Remove air duct Refer to EM 16 Removal and Installation 2 Remove the undercover using power tool 3 Remove the radiator shroud lower Refer to CO 14 Removal and Installation 4 5 Remove drive belts Refer to EM 15 Removal and Installation Remove cooling fan INSPECTION AFTER REMOVAL Inspect fan coupling for oil leakage and bimetal conditions SLC072 INSTALLATION Install in the reverse order of removal referring the following e Install cooling fan with its
4. ee ee ee nee ee Go Se Ee 26 System Chart sesse aeai aa ee RA R ee 10 Removal and Installation ee ee ee AA ee 26 ENGINE COOLANT esse eene ese sae Rae ee RE Re AR RE Gee Ke e 11 aldie LERE EE a senian aian aS 26 lei EO RE N 11 INSPECTION AFTER REMOVAL esse sesse ee 28 LEVEL CHECK it RE ef Ee EE Ke 11 INSTALLATION is Ee EE ee EER ee an gese ed 28 LEAKGHEGK MA a N etes ee ee ER Gee GE ee 11 INSPECTION AFTER INSTALLATION ie 29 Changing Engine Coolant s es 11 THERMOSTAT AND THERMOSTAT HOUSING 30 DRAINING ENGINE COOLANT esse sesse ee 11 Removal and Installation ee ee ee 30 REFILLING ENGINE COOLANT oaeee 12 REMOVAL re ee itech aha ele 30 FLUSHING COOLING SYSTEM ose 13 INSPECTION AFTER REMOVAL sees sesse 30 RADIATOR oe an EE ee Oe ban Ee See 14 INSTALEATION amp Eier see RR See ge ie bree aaran ta 30 Removal and Installation a e 14 INSPECTION AFTER INSTALLATION ie 31 REMOVA Ee REIS RE tte se dee ee a Ed 15 WATER OUTLET AND WATER PIPING 00 32 INSTALLATION ee ee ee ee ee aa aaa aiaa 17 Removal and Installation ees ee ee 32 Checking Radiator Cap iese ee ee ee ee ee 17 REMOVAL sessies tiese Ee beg ese des gee Ere die 32 Checking Radiator ee see ee AA ee ee 17 INSTALLATION oies casa ee ee ee RA ee 32 RADIATOR ALUMINUM TYPE nee eene sea 18 INSPECTION AFTER INSTALLATION 33 Disassembly and Assembly enesesse 18 SERVICE DATA AND SPECIFICATIONS S
5. in Ib If water drain plugs on cylinder block are removed close and tighten them Refer to EM 111 ASSEMBLY 2 Remove air relief plug on heater hose Z LF o Air relief plug f l n TON 9 Oy AD A EA y W N D A AN AGS SNe Front PBIC1050E ce N 3 Fill radiator with water until water spills from the air relief hole then close air relief plug Fill radiator and reservoir tank with water and reinstall radiator cap Air relief plug 9 0 78 1 6 N m 0 08 0 16 kg m 7 14 in Ib Run engine and warm it up to normal operating temperature Rev engine two or three times under no load Stop engine and wait until it cools down Drain water from the system Refer to CO 11 DRAINING ENGINE COOLANT Repeat steps 1 through 7 until clear water begins to drain from radiator ONOAS Revision 2004 April CO 13 2003 G35 Sedan RADIATOR RADIATOR Removal and Installation SEC 214 A T models fw 5 7 6 5 0 59 0 66 51 57 in Ky 3 8 4 5 PFP 21400 ABS0002J Kg 3 8 4 5 0 39 0 45 34 39 To water outlet io 0 39 0 45 34 39 s ar A T fluid O cooler tube 0 08 0 16 7 14 OG Always replace after every disassembly 9 Nem kg m in Ib 1 Reservoir tank 2 Cap 4 Radiator hose upper 5 Radiator cap 7 Mounting rubber upper 8 Radiator 10 Mounting rubber lower 11 Drain plug 13 A T f
6. 16 AIR CLEANER AND AIR DUCT 6 Remove bracket mounting bolt for anchoring A C piping from vehicle left side so that A C piping can be moved 7 Remove reservoir tank and bracket 8 Remove radiator hoses upper and lower and reservoir tank hose CAUTION Be careful not to allow engine coolant to contact drive belts Revision 2004 April CO 15 2003 G35 Sedan RADIATOR 9 Remove radiator cooling fan assembly Refer to CO 24 Removal and Installation Motor Driven M T Models M T models 10 Remove radiator shroud lower A T models e While pressing left and right pawls in direction indicated by arrows pull lower radiator shroud toward you to remove va gt i rial PBICO838E 11 Remove radiator shroud A T models 12 Remove cooling fan Refer to CO 22 Removal and Installation Crankshaft Driven Type A T Models A T models 13 Rotate two radiator upper mount brackets 90 degrees in the direction as shown in the figure and remove them 14 Remove two A C condenser mounting bolts located in upper part of radiator PBICO840E 15 Remove radiator as follows CAUTION Do not damage or scratch A C condenser and radiator core when removing a With lifting and pulling radiator in a rear direction disassemble lower mount from radiator core support center ee condenser CAUTION Because A C condenser is onto the front lower portion of radiator moving to rear direction should be at minimum R
7. B ENGINE SECTION C O ENGINE COOLING SYSTEM CONTENTS APPLICATION NOTICE e sees ees ee Rae Re AR RE EES 2 Removal and Installation Crankshaft Driven Type How to Check Vehicle Type iis ee see se de 2 AIT EES EN ER casi eeteeetivints 22 PRECAUTIONS ie Ene been Bee RE Re ee ea lees eR Ese ee 3 REMOVAL i EE RE EE N 22 Precautions for Supplemental Restraint System INSPECTION AFTER REMOVAL ees esse ees 22 SRS AIR BAG and SEAT BELT PRE TEN INSTALLATION ee ee ee ee ke a ee ee 22 SIONER visit ees bena et gee ge bek ATE aaa eed ees 3 Removal and Installation Motor Driven Type A Precautions for Liquid Gasket a se 3 1T ee EE EEN 23 REMOVAL OF LIQUID GASKET SEALING 3 REMOVAL GIS iin ee ke De ge n lane 23 LIQUID GASKET APPLICATION PROCEDURE 3 INSTALLATION ee ee Re ee ee RA ee Re 23 PREPARATION 5 etes see ee ee ee dese Oes geed ees ee Oe 5 DISASSEMBLY AND ASSEMBLY 008 23 Special Service Tools cceeccceeeeeeeeeeeeseeeeeeeseeees 5 Removal and Installation Motor Driven M T Mod Commercial Service Tools n 6 AE EA ME OE te tit ila ed 24 OVERHEATING CAUSE ANALYSIS cssteeeees 7 REMOVAL aeeoo EE EE RD 24 Troubleshooting Chart ese ee ee 7 INSTALLATION s5 iseer ke ese edge bee er be ed askese is 24 COOLING SYSTEM see ese ee ee ee Rae EE EE AR RE GE ER EES 9 DISASSEMBLY AND ASSEMBLY ees 25 Cooling Circuit entin ee ke ee ee 9 WATER PUMP ER Ge
8. CTS AND SEAL ANTS VI Tube presser 2 3 3 3 mm Fa Apply Genuine RTV 0 091 0 130 in silicone sealant or equivalent Refer to GI section PBIC1283E 8 Install water drain plug on water pump side of cylinder block N CO Apply G silicone sealant or equivalent 2 Refer to GI section PBICOBAGE 9 Installation is in the reverse order of removal for remaining parts e 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 the chain tensioner The engine may produce a rat tling noise This indicates that air still remains in the chamber and is not a matter of concern INSPECTION AFTER INSTALLATION e Check for leaks of engine coolant using radiator cap tester adapter special service tool EG17650301 J33984 A and radiator cap tester commercial service tool Refer to CO 11 LEAK CHECK e Start and warm up engine Visually make sure that there is no leaks of engine coolant and A T fluid A T models Revision 2004 April CO 29 2003 G35 Sedan THERMOSTAT AND THERMOSTAT HOUSING THERMOSTAT AND THERMOSTAT HOUSING PFP 21200 Removal and Installation EO SEC 210 211 O N To oil cooler 0 9 1 1 75 95 o Nem kg m in ib gt lt Always replace after every disassembly PBIC1669E EMOVAL Remove undercover using power tools Drain engine coolant from the radiator Refer to CO 11 Changing Engine Coo
9. DS 34 PREPARATION ie ei SEER Ska ek Pe ie ee ees eed ges 18 Engine Coolant Capacity Approximate 34 DISASSEMBLY ees ee see ee ee ee ee ee ee ee ee 18 Thermostat EERSTE BENE SEED EEK EE de DEK E SE RENE EE Ne Ps 34 ASSEMBLY ER ve ee nan Aint 19 Radiator Ee An ceil EG EE aah se bee be ee GE ge eg 34 INSPECTION ees ee ee ee ee ee ee a Re ee 21 Tightening TOrgue aeaa ee ee AA ae 34 COOLING FAN etes s ees aat ge sees ee soe SE Ee 22 Revision 2004 April CO 1 2003 G35 Sedan APPLICATION NOTICE APPLICATION NOTICE PFP 00000 How to Check Vehicle Type aBso0ce Check the transmission and vehicle serial number to confirm the service information in EC section Transmission Vehicle serial number Service information Up to serial 329287 except 327918 327920 TYPE 1 327976 327978 328979 329004 329025 329078 A T For serial 327918 327920 327976 327978 328979 329004 329025 329078 and TYPE 2 from serial 329288 M T Revision 2004 April CO 2 2003 G35 Sedan PRECAUTIONS PRECAUTIONS PFP 00001 Precautions for Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER aBs00ss0 The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER used along 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 This system includes seat belt switch inputs and dual stage front
10. FAN Removal and Installation Motor Driven M T Models 48500860 SEC 214 Wy 2 9 3 9 0 30 0 39 26 34 EA Apply on fan motor shaft kol 3 9 4 9 0 40 0 49 35 43 wy 3 8 4 5 N 0 39 0 45 34 39 hy 3 9 4 9 0 40 0 49 35 a Apply thread locking sealant 9 Nem kg m in 1b PBIC1924E 1 Cooling fan RH 2 Cooling fan LH 3 Fan shroud 4 Fan motor REMOVAL 1 Drain engine coolant from the radiator Refer to CO 11 Changing Engine Coolant CAUTION e Perform when the engine is cold e Do not spill engine coolant on drive belts 2 Remove air duct inlet power duct and air cleaner case assembly Refer to EM 16 AIR CLEANER AND AIR DUCT 3 Disconnect radiator upper hose 4 Disconnect fan motor harness connectors at the right lower por S tion of fan shroud N NQ O Ml Harness connector WANK Blk 7 ZAM OD Sete front PBIC1935E 5 Remove radiator cooling fan assembly CAUTION Be careful not to damage or scratch on radiator core INSTALLATION Install in the reverse order of removal e Cooling fan is controlled by ECM For details refer to EC 1135 DTC P1217 ENGINE OVER TEMPERA TURE FOR M T MODELS Revision 2004 April CO 24 2003 G35 Sedan COOLING FAN DISASSEMBLY AND ASSEMBLY Disassembly 1 Remove cooling fans from fan motors 2 Remove fan motors from fan shroud Assembly Assemble in the reverse order of disassemb
11. To check for leaks apply pressure to the cooling system with radiator cap tester commercial service tool and radiator cap D tester adapter SST J Testing pressure 157 kPa 1 6 kg cm 23 psi WARNING EG17650301 Do not remove radiator cap when engine is hot Serious 33984 A burns could occur from high pressure engine coolant escaping from radiator CAUTION Higher test pressure than specified may cause radiator damage NOTE In a case engine coolant decreases replenish radiator with engine coolant e f anything is found repair or replace damaged parts Changing Engine Coolant 48500008 WARNING e To avoid being scalded never change the engine coolant when the engine is hot e Wrap a thick cloth around cap and carefully remove the cap First turn the cap a quarter of a turn to release built up pressure Then turn the cap all the way e Be careful not to allow engine coolant to contact drive belts DRAINING ENGINE COOLANT 1 Remove undercover with power tool 2 Open radiator drain plug at the bottom of radiator and then jp remove radiator cap Hose adapter Front ___ qa PBICO893E When drain all of engine coolant in the system open water drain plugs on engine cylinder block Refer to EM 106 DISASSEMBLY 3 Remove reservoir tank as necessary and drain engine coolant and clean reservoir tank before installing Revision 2004 April CO 11 2003 G35 Sedan ENGINE COOLANT 4 Check drain
12. adiator Vehicle amp o front Mounting rubber lower Radiator core support center PBIC1936E Revision 2004 April CO 16 2003 G35 Sedan b RADIATOR Lift A C condenser up and remove radiator after disengaging the fitting as front bottom surface CAUTION Lifting A C condenser should be minimum to prevent a load to A C piping After removing radiator put A C condenser on radiator core sup gt nes Radiator port center to prevent a load to A C piping and temporarily fix it SE ee D with a rope or similar means whe INSTALLATION Install in the reverse order of removal Checking Radiator Cap agsoo7zy 1 Pull the negative pressure valve to open it and check that it closes completely when released e Check that there is no dirt or damage on the valve seat of the radiator cap negative pressure valve e Check that there are no unusualness in the opening and clos ing conditions of the negative pressure valve Check radiator cap relief pressure Standard 78 98 kPa 0 8 1 0 kg cm 11 14 psi Limit 59 kPa 0 6 kg cm 9 psi e When connecting the radiator cap to the tester apply engine coolant to the cap seal surface e Replace the radiator cap if there is an unusualness in the neg ative pressure valve or if the open valve pressure falls below 333984 A the limit SLC755A Checking Radiator apsoo7zz Check radiator for mud or clogging If necessary clean radiator as follows
13. air bag modules The SRS system uses the seat belt switches to determine the front air bag deployment and may only deploy one front air bag depending on the severity of a collision and whether the front occupants are belted or unbelted Information necessary to service the system safely is included in the SRS and SB section of this Service Man ual WARNING e 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 per formed by an authorized NISSAN INFINITI dealer e Improper maintenance including incorrect removal and installation of the SRS can lead to per sonal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SRS section e Donot 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 harness connectors Precautions for Liquid Gasket AESOOONM REMOVAL OF LIQUID GASKET SEALING e After removing the mounting bolts and nuts separate the mating surface using seal cutter special service tool and remove the O 9 old liquid gasket sealing tore 11100 CAUTION gt Ce Be careful not to damage the mating surfaces je e In areas where the cutter is difficult to use use a plastic hammer to light
14. an Refer to CO 22 Removal and Installation Crankshaft Driven Type A T Models A T models 8 Radiator cooling fan assembly Refer to CO 24 Removal and Installation Motor Driven M T Models M T models 9 Remove water drain plug on water pump side of cylinder block 10 Remove chain tensioner cover and water pump cover Chain ne ee ae e Use seal cutter special service tool KV10111100 J37228 cx DV cover or equivalent tool to cut liquid gasket for remove KCB 11 Remove the chain tensioner assembly with the following proce e D dure A A 0 L Zi a Pull the lever down and release the plunger stopper tab SS Ts TE drain plug e Plunger stopper tab can be pushed up to release coaxial LAL IO a structure with lever silicone sealant or equivalent Refer to GI section PBIC0846E Revision 2004 April CO 26 2003 G35 Sedan WATER PUMP b Insert the stopper pin into the tensioner body hole to hold the lever and keep the stopper tab released Plunger stopper tab NOTE An allen wrench 2 5 mm 0 098 in is used for a stopper pin as an example c Insert the plunger into the tensioner body by pressing the timing chain slack guide d Keep the slack guide pressed and hold the plunger in by push WI Y ing the stopper pin deeper through the lever and into the ten Stopper pin sioner body hole Slack guide Plunger SLC444B e Turn crankshaft pulley clockwise so that the timing chain on the c
15. dels Revision 2004 April CO 31 2003 G35 Sedan WATER OUTLET AND WATER PIPING WATER OUTLET AND WATER PIPING PFP 11060 Removal and Installation FT SEC 2102211253 To intake manifold or ee ee 21 collector upper 6 3 8 3 ay 0 65 0 84 Wl 6 3 8 3 0 65 Kn 73 To ngater Fa d a ia l Lo a g A 0 24 5 31 4 2 5 3 2 18 23 0 21 6 27 4 To 2 2 2 7 O 16 20 s collector upper 47 O 24 5 31 4 2 5 8 2 18 23 2 Always replace after every disassembly fg N m kg m in ib O Nem kg m ft lb fy 9 8 12 7 1 0 1 2 87 112 PBIC1060E 1 Harness bracket 2 Water hose 3 Water bypass hose 4 Engine coolant temperature sensor 5 Gasket 6 Water outlet 7 Heater hose 8 Water pipe 9 Radiator upper hose 10 Heater pipe REMOVAL 1 Remove undercover using power tools 2 Drain engine coolant from drain plugs on radiator and both sides of cylinder block Refer to GO 11 Changing Engine Coolant 3 Remove engine cover Refer to EM 18 REMOVAL 4 Remove air duct and air cleaner case Refer to EM 16 Removal and Installation 5 Remove radiator upper hose and heater hose 6 Remove the following parts when remove water outlet e A T fluid charging pipe A T models Refer to AT 329 TRANSMISSION ASSEMBLY e Intake manifold collectors upper and lower Refer to EM 18 INTAKE MANIFOLD COLLECTOR e Rocker cover right ban
16. ed engine coolant for contaminants such as rust corrosion or discoloration If contaminated flush the engine cooling system Refer to CO 13 FLUSHING COOLING SYSTEM REFILLING ENGINE COOLANT 1 Install reservoir tank and radiator drain plug CAUTION Be sure to clean drain plug and install with new O ring Radiator drain plug 9 0 78 1 6 N m 0 08 0 16 kg m 7 14 in Ib If water drain plugs on cylinder block are removed close and tighten them Refer to EM 111 ASSEMBLY 2 Make sure that each hose clamp has been firmly tightened 3 Remove air relief plug on heater hose 4 Fill radiator and reservoir tank to specified level e Pour engine coolant through engine coolant filler neck slowly of less than 2 2 1 8 US qt 1 3 4 Imp qt a minute to allow air in system to escape e Use Genuine Nissan Long Life Antifreeze Coolant or equivalent mixed with water distilled or demineralized Refer to MA 11 RECOMMENDED FLUIDS AND LUBRI CANTS Engine coolant capacity Approximate with reservoir tank at MAX level 8 5 9 US qt 7 1 2 Imp qt for A T models 8 7 9 1 4 US qt 7 5 8 Imp qt for M T models Radiator SMA182B Reservoir tank engine coolant capacity at MAX level 0 8 7 8 US at 3 4 Imp qt e When engine coolant overflows air relief hole on heater hose install air relief plug with new O ring Air relief plug 0 78 1 6 N m 0 08 0 16 kg m 7 14 in Ib SMA412B 5 I
17. front mark F facing front of engine Refer to Component Parts Illustration CO 22 Removal and Installation Crankshaft Driven Type A T Models Revision 2004 April CO 22 2003 G35 Sedan COOLING FAN Removal and Installation Motor Driven Type A T Models REMOVAL 1 Remove front grille Refer to El 20 FRONT GRILLE 2 Remove the under cover using power tool 3 Disconnect harness connector from fan motor 4 Remove fan grille INSTALLATION Install in the reverse order of removal SEC 214 0 58 0 66 kg m 51 57 in Ib XK NE N RON IH A s S AS N ABS000JO ANY SAN NNN CA M y IN NA N Vs Oe N OO PBICO843E e Cooling fan is controlled by ECM For details refer to EC 509 DTC P1217 ENGINE OVER TEMPERA TURE TYPE 2 DISASSEMBLY AND ASSEMBLY SEC 214 s g 3 9 FAO Apply genuine high strength locking sealant or equivalent Refer to GI section MS Nem kg m in Ib 1 Cooling fan 2 6 5 0 58 Fan grille Disassembly 1 Remove cooling fan from fan motor 2 Remove fan motor from fan grille Assembly Assemble in the reverse order of disassembly Revision 2004 April CO 23 4 9 0 40 fy 2 9 TYPE 1 or EG 1123 DTG P1217 ENGINE OVER TEMPERATURE FOR A T MODELS 0 49 35 43 3 9 0 30 0 39 26 FO Apply on fan motor shaft 0 66 51 3 Fan motor PBIC2669E 2003 G35 Sedan COOLING
18. hain tensioner side is loose Crankshaft pulley PBIC1805E 12 Remove chain tensioner CAUTION Be careful not to drop mounting bolts inside chain case 13 Remove the three water pump fixing 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 Lory He Crankshaft pulley PBIC1193E 14 Screw M8 bolts pitch 1 25 mm 0 049 in length approx 50 mm 1 97 in into water pumps upper and lower mounting bolt C d holes until they reach timing chain case Then alternately E tighten each bolt for a half turn and pull out water pump e Pull straight out while preventing vane from contacting socket in installation area e Remove water pump without causing sprocket to contact tim ing chain 15 Remove M8 bolts and O rings from water pump CAUTION Do not disassemble water pump Revision 2004 April CO 27 2003 G35 Sedan WATER PUMP INSPECTION AFTER REMOVAL e Check for badly rusted or corroded water pump body assembly e Check for rough operation due to excessive end play e Replace water pump if necessary SLC943A INSTALLATION 1 Install new O rings to water pump e Apply engine oil and engine coolant to the O rings as shown e Locate the O ring with white paint mark to engine front side White paint O ring Black FY O ring Black 3 Apply engine coolant Always re
19. il CO 6 2003 G35 Sedan OVERHEATING CAUSE ANALYSIS OVERHEATING CAUSE ANALYSIS Troubleshooting Chart Symptom Check items PFP 00012 ABS0001H Cooling sys tem parts malfunction Poor heat transfer Water pump malfunction Worn or loose drive belt Thermostat stuck closed Damaged fins Dust contamination or paper clogging Physical damage Clogged radiator cooling tube Excess foreign material rust dirt sand etc Reduced air flow Cooling fan does not oper ate High resistance to fan rota tion Damaged fan blades Fan assembly Damaged radiator shroud Improper engine coolant mixture ratio Poor engine coolant quality Engine coolant viscosity Insufficient engine coolant Revision 2004 April Engine coolant leaks Loose clamp Cooling hose Cracked hose Water pump Poor sealing f Loose Radiator cap Poor sealing Radiator O ring for damage deterio ration or improper fitting Cracked radiator tank Cracked radiator core Reservoir tank Cracked reservoir tank Overflowing reservoir tank CO 7 Exhaust gas leaks into cooling system Cylinder head deterioration Cylinder head gasket dete rioration 2003 G35 Sedan OVERHEATING CAUSE ANALYSIS Symptom Check items Except cool ing system parts mal function Overload on engine High engine rpm under no load Drivi
20. k Refer to EM 43 ROCKER COVER 7 Remove engine coolant temperature sensor as necessary CAUTION Be careful not to damage engine coolant temperature sensor 8 Remove water outlet heater pipe water bypass hoses and water pipe INSTALLATION Install in the reverse order of removal e Securely insert each hose and install a clamp at a position where it does not interfere with the pipe bulge e When inserting a water pipe into water outlet apply neutral detergent to O ring Revision 2004 April CO 32 2003 G35 Sedan WATER OUTLET AND WATER PIPING INSPECTION AFTER INSTALLATION e Check for leaks of engine coolant using radiator cap tester adapter special service tool EG17650301 J33984 A and radiator cap tester commercial service tool Refer to CO 11 LEAK CHECK e Start and warm up engine Visually make sure that there is no leaks of engine coolant joo 00 Revision 2004 April CO 33 2003 G35 Sedan SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS Engine Coolant Capacity Approximate PFP 00100 ABS0001Q A T 8 5 0 9 US qt 7 1 2 Imp qt Engine coolant capacity With reservoir tank at MAX level M T 8 7 9 1 4 US qt 7 5 8 Imp qt Reservoir tank engine coolant capacity at MAX level 0 8 7 8 US qt 3 4 Imp at Thermostat aBso001R Valve opening temperature gil A M T 76 5 C 170 F Vaii A T 8 6 mm 95 C 0 339 in 203
21. lant Remove air duct Refer to EM 16 Removal and Installation Remove water drain plug on water pump side of the engine Refer to CO 26 WATER PUMP Remove radiator lower hose from thermostat and thermostat housing Remove oil cooler water hose from thermostat and thermostat housing Remove thermostat and thermostat housing Thermostat and e Do not disassemble thermostat and thermostat housing thermostat housing Replace them as a unit if necessary R 1 2 3 4 5 6 7 PBIC1398E INSPECTION AFTER REMOVAL 1 Check valve seating condition at ordinary room temperatures It should seat tightly 2 Check valve opening temperature and maximum valve lift Thermostat Standard A T 82 C 180 F Valve opening temperature M T 76 5 C 170 F A T 8 6 mm 95 C 0 339 in 203 F Valve lift M T 8 6 mm 90 C 0 339 in 194 F 3 Then check if valve closes at 5 C 9 F below valve opening temperature SLC949A INSTALLATION Install in the reverse order of removal Revision 2004 April CO 30 2003 G35 Sedan THERMOSTAT AND THERMOSTAT HOUSING INSPECTION AFTER INSTALLATION e Check for leaks of engine coolant using radiator cap tester adapter special service tool EG17650301 J33984 A and radiator cap tester commercial service tool Refer to CO 11 LEAK CHECK e Start and warm up engine Visually make sure that there is no leaks of engine coolant and A T fluid A T joo 00 mo
22. luid cooler hose 14 Radiator shroud 16 Bracket Revision 2004 April CO 14 Ne 3 8 4 5 0 39 0 45 34 39 PBIC1985E Reservoir tank hose Upper mount bracket Radiator hose lower O ring Radiator shroud lower 2003 G35 Sedan RADIATOR SEC 214 las as M T models 0 39 0 45 34 39 Kg 5 7 6 5 er z 1 To water outlet pa 3 8 4 5 k 0 39 0 45 34 39 To water Da oan Refer to COOLING FAN in CO section aa is o wy 0 78 1 6 0 08 0 16 7 14 G Always replace after every disassembly 9 Nem kg m in Ib PBIC1984E 1 Reservoir tank 2 Cap 3 Reservoir tank hose Radiator hose upper 5 Radiator cap 6 Upper mount bracket 7 Mounting rubber upper 8 Radiator 9 Radiator hose lower 10 Mounting rubber lower 11 Drain plug 12 O ring 13 Radiator cooling fan assembly 14 Bracket WARNING Never remove the radiator cap when the engine is hot Serious burns could occur from high pressure engine coolant escaping from the radiator REMOVAL 1 Remove engine cover with power tool Refer to EM 18 INTAKE MANIFOLD COLLECTOR 2 Remove undercover with power tool 3 Drain engine coolant from radiator Refer to CO 11 Changing Engine Coolant CAUTION Perform when the engine is cold 4 Disconnect A T fluid cooler hoses A T models e Install blind plug to avoid leakage of A T fluid 5 Remove air duct inlet and air cleaner case Refer to EM
23. ly Revision 2004 April CO 25 2003 G35 Sedan WATER PUMP WATER PUMP PFP 21020 Removal and Installation ESE SEC 130 135 210 OFF 7 8 11 8 0 8 1 2 69 104 fy 6 9 9 3 0 70 0 94 61 82 O N A NN oa 10 8 fe 9 8 12 8 oo 0 9 1 1 75 95 KR i 1 0 1 3 87 113 C poo SY Og engine coolant ro N 3 ol Nem kg m in lb N a Identify with white Apply Genuine RTV silicone sealant or equivalent Refer to GI section paint mark Ki Lubricate with new engine oil Always replace after every disassembly PBIC1288E 1 Chain tensioner 2 Chain tensioner cover 3 Water pump cover 4 Water pump 5 O rings 6 Water drain plug front CAUTION e When removing water pump assembly be careful not to get engine coolant on drive belt e Water pump cannot be disassembled and should be replaced as a unit e After installing water pump connect hose and clamp securely then check for leaks using radiator cap tester REMOVAL 1 Remove undercover using power tools 2 Remove drive belts Refer to EM 15 Removal and Installation 3 Drain engine coolant from radiator Refer to CO 11 Changing Engine Coolant CAUTION Perform when the engine is cold 4 Remove air duct Refer to EM 16 Removal and Installation 5 Remove radiator upper hose and lower hoses A T models 6 7 Remove radiator shrouds A T models Remove cooling f
24. ly tap the areas where the liquid gasket is applied CAUTION If for some unavoidable reason a tool such as a flat bladed screwdriver is used be careful not to damage the mating surfaces LIQUID GASKET APPLICATION PROCEDURE 1 Using a scraper remove the old liquid gasket adhering to the liq uid gasket application surface and the mating surface e Remove the 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 face removing any adhering moisture grease and foreign mate rial oe j Slide PBICOOO2E PBICOOOSE Revision 2004 April CO 3 2003 G35 Sedan PRECAUTIONS 3 Attach the liquid gasket tube to the tube presser special service tool WS39930000 j Use Genuine RTV Silicone Sealant or equivalent Refer to GI 45 RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS 4 Apply the liquid gasket without breaks to the specified location with the specified dimensions e If there is a groove for the liquid gasket application apply the liquid gasket to the groove e As for the bolt holes normally apply the liquid gasket inside Inner the holes Occasionally it should be applied outside the side holes Make sure to read the text of this manual e Within five minutes of liquid gasket application install the mat ing component e If the liquid gasket
25. ng in low gear for Abusive driving Ode tine Driving at extremely high speed Powertrain system mal function Installed improper size wheels and tires Dragging brakes Improper ignition timing Blocked or restricted air flow Blocked bumper Blocked radiator grille Installed car brassiere Mud contamination or paper clogging Blocked radiator Blocked condenser Blocked air flow Installed large fog lamp Revision 2004 April CO 8 2003 G35 Sedan COOLING SYSTEM COOLING SYSTEM Cooling Circuit To heater Ee ET e To intake manifold collector upper PFP 21020 ABS00011 From heater Cylinder block LH A From intake manifold collector upper Cylinder head Left bank Water pump Cylinder head Right bank Revision 2004 April CO 9 ERNA ay N 2 Thermostat d Water inlet Radiator PBIC2073E 2003 G35 Sedan System Chart f f i i Reservoir tank Radiator Cylinder head Revision 2004 April COOLING SYSTEM Thermostat CO 10 Oil cooler ABSO0CGJ Intake manifold collector PBICO847E 2003 G35 Sedan ENGINE COOLANT ENGINE COOLANT PFP KQ100 Inspection aBsooo1s LEVEL CHECK e Check if the reservoir tank engine coolant level is within the MIN to MAX when the engine is cool e Adjust the engine coolant level as necessary SMA412B LEAK CHECK e
26. nstall radiator cap 6 Warm up until opening thermostat Standard for warming up time is approximately 10 minutes at 3 000 rpm e Make sure 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 engine and cool down to less than approximately 50 C 122 F Revision 2004 April CO 12 2003 G35 Sedan ENGINE COOLANT e Cool down using fan to reduce the time e If necessary refill radiator up to filler neck with engine coolant 8 Refill reservoir tank to MAX level line with engine coolant 9 Repeat steps 4 through 7 two or more times with radiator cap installed until engine coolant level no longer drops 10 Check cooling system for leaks with engine running 11 Warm up engine and check for sound of engine coolant flow while running engine from idle up to 3 000 rpm with heater temperature controller set at several position between COOL and WARM e Sound may be noticeable at heater unit 12 Repeat step 10 three times 13 If sound is heard bleed air from cooling system by repeating step 4 through 7 until engine coolant level no longer drops e Clean excess engine coolant from engine FLUSHING COOLING SYSTEM 1 Install reservoir tank and radiator drain plug CAUTION Be sure to clean drain plug and install with new O ring Radiator drain plug 0 78 1 6 N m 0 08 0 16 kg m 7 14
27. pe cial service tool CAUTION Do not disassemble lower tank and A T fluid cooler NOTE Regard lower tank and A T fluid cooler as an assembly Revision 2004 April CO 18 2003 G35 Sedan RADIATOR ALUMINUM TYPE e Grip the crimped edge and bend it upwards so that radiator plate pliers B slips off CAUTION Do not bend excessively SLC893 e In areas where radiator plate pliers B cannot be used use flat blade screwdriver to bend the edge up CAUTION Be careful not to damage tank SLC930 2 Remove sealing rubber 3 Make sure the edge stands straight up HH S LO SLC931 ASSEMBLY 1 Clean contact portion of tank SLC932 Revision 2004 April CO 19 2003 G35 Sedan RADIATOR ALUMINUM TYPE 2 Install sealing rubber while pushing it with fingers CAUTION Be careful not to twist sealing rubber 3 Caulk tank in numerical order as shown in the figure with radia tor plate pliers A special service tool 9103510 _ SLC904 A Keep Tool perpendicular to the radiator Grip is insufficient PRICSO76E e Use pliers in the locations where radiator plate pliers A cannot be used SLC897 Revision 2004 April CO 20 2003 G35 Sedan RADIATOR ALUMINUM TYPE 4 Make sure that the rim is completely crimped down Standard height H 8 0 8 4 mm 0 315 0 331 in SLC554A 5 Make sure that there is no leakage Refer to CO 21
28. place after every disassembly Lubricate with new engine oil AE 2 Install the water pump e Do not allow cylinder block to nip the O rings when installing the water pump e Check that timing chain and water pump sprocket are engaged e Insert water pump by tightening mounting bolts alternately and evenly PBIC1058E 3 Remove dust and foreign material completely from backside of chain tensioner and from installation area of rear timing chain case 4 Turn the crankshaft pulley clockwise so that the timing chain on the timing chain tensioner side is loose e When installing the timing chain tensioner engine oil should be applied to the oil hole and ten sioner 5 Install the timing chain tensioner 6 Remove the stopper pin SLC448B 7 Install chain tensioner cover and water pump cover Revision 2004 April CO 28 2003 G35 Sedan WATER PUMP a Before installing remove all traces of liquid gasket from mating surface of water pump cover and chain tensioner cover using a scraper Also remove traces of liquid gasket from the mating sur face of the front cover Chain tensioner cover Water pump cover SLC446B b Apply a continuous bead of liquid gasket using tube presser special service tool WS39930000 to mating surface of chain tensioner cover and water pump cover Use Genuine RTV Silicon Sealant or equivalent Refer to Gl T Water pump cover Chain tensioner cover 45 RECOMMENDED CHEMICAL PRODU
29. protrudes wipe it off immediately e Do not retighten after the installation e After 30 minutes or more have passed from the installation fill the engine oil and engine coolant CAUTION If there are specific instructions in this manual observe them Inner side SEM159F Revision 2004 April CO 4 2003 G35 Sedan PREPARATION PREPARATION PFP 00002 Special Service Tools ABso0oiF The actual shapes of Kent Moore tools may from those of special service tools illustrated here Tool number CO Kent Moore No Description Tool name WS39930000 Pressing the tube of liguid gasket Tube pressure S NTO52 EG17650301 Adapting radiator cap tester to radiator cap J33984 A and radiator filler neck Radiator cap tester adapter mee a 28 1 10 dia O F ot fst b 31 4 1 236 dia c 41 3 1 626 dia KS amp ptt Unit mm in S NT564 KV99103510 Installing radiator upper and lower tanks Radiator plate pliers A S NT224 KV99103520 Removing radiator upper and lower tanks 7 Radiator plate pliers B S NT225 KV10111100 Removing chain tensioner cover and water J37228 pump cover Seal cutter NT046 Revision 2004 April CO 5 2003 G35 Sedan PREPARATION Commercial Service Tools 8500016 Tool name Description Power tool Loosening bolts and nuts PBICO190E Radiator cap tester Checking radiator and radiator cap PBIC1982E Revision 2004 Apr
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