2001 NISSAN PICK-UP engine overheat

Overall Function Check
Use this procedure to check the overall function of the cooling
fan. During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Seri-
ous burns could be caused by high pressure fluid escaping
from the radiator.
Wrap a thick cloth around the cap. Carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape. Then turn the cap all the way off.
WITH CONSULT-II
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is
below the proper range, skip the following steps and go to
ªDiagnostic Procedureº, EC-3494.
2) Confirm whether customer filled the coolant or not. If cus-
tomer filled the coolant, skip the following steps and go to
ªDiagnostic Procedureº, EC-3494.
3) Turn ignition switch ªONº.
4) Perform ªCOOLING FANº in ªACTIVE TESTº mode with
CONSULT-II and make sure that cooling fans operate when
touching ªONº or ªOFFº.
If NG, go to ªDiagnostic Procedureº, EC-3494.
WITHOUT CONSULT-II
1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is
below the proper range, skip the following steps and go to
ªDiagnostic Procedureº, EC-3494.
2) Confirm whether customer filled the coolant or not. If cus-
tomer filled the coolant, skip the following steps and go to
ªDiagnostic Procedureº, EC-3494.
3) Disconnect engine coolant temperature sensor harness con-
nector.
4) Connect 150Wresistor to engine coolant temperature sensor
harness connector.
5) Start engine and make sure that cooling fan operates.
Be careful not to overheat engine.
6) If NG, go to ªDiagnostic Procedureº, EC-3494.
AEC640
SEF111X
SEC636CA
DTC 0208 OVER HEATYD25DDTi
EC-3491

18 CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go to ªMAIN 12 CAUSES OF OVERHEATINGº, EC-3501.
cINSPECTION END
Main 12 Causes of Overheating
Engine Step Inspection item Equipment Standard Reference page
OFF 1+Blocked radiator
+Blocked condenser
+Blocked radiator grille
+Blocked bumper+Visual No blocking Ð
2+Coolant mixture+Coolant tester 30 - 50% coolant mixture See ªRECOMMENDED
FLUIDS AND LUBRI-
CANTSº in MA section.
3+Coolant level+Visual Coolant up to MAX level
in reservoir tank and
radiator filler neckSee ªChanging Engine
Coolantº, ªENGINE MAIN-
TENANCEº in MA sec-
tion.
4+Radiator cap+Pressure tester 78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0
kg/cm
2, 11 - 14 psi)
59 - 98 kPa (0.59 - 0.98
bar, 0.6 - 1.0 kg/cm
2,
9 - 14 psi) (Limit)See ªSystem Checkº,
ªENGINE COOLING SYS-
TEMº in LC section.
ON*2 5+Coolant leaks+Visual No leaks See ªSystem Checkº,
ªENGINE COOLING SYS-
TEMº in LC section.
ON*2 6+Thermostat+Touch the upper and
lower radiator hosesBoth hoses should be hot. See ªThermostatº and
ªRadiatorº, ªENGINE
COOLING SYSTEMº in
LC section.
ON*1 7+Cooling fan+Visual Operating See ªDTC 0208 OVER
HEATº, EC-3489.
OFF 8+Combustion gas leak+Color checker chemical
tester 4 gas analyzerNegative Ð
ON*3 9+Coolant temperature
gauge+Visual Gauge less than 3/4
when drivingÐ
+Coolant overflow to res-
ervoir tank+Visual No overflow during driving
and idlingSee ªChanging Engine
Coolantº, ªENGINE MAIN-
TENANCEº in MA sec-
tion.
OFF*4 10+Coolant return from res-
ervoir tank to radiator+Visual Should be initial level in
reservoir tankSee ªENGINE MAINTE-
NANCEº in MA section.
OFF 11+Cylinder head+Straight gauge feeler
gauge0.1 mm (0.004 in) Maxi-
mum distortion (warping)See ªInspectionº, ªCYLIN-
DER HEADº in EM sec-
tion.
12+Cylinder block and pis-
tons+Visual No scuffing on cylinder
walls or pistonSee ªInspectionº, ªCYLIN-
DER BLOCKº in EM sec-
tion.
*1: Engine running at idle.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to ªOVERHEATING CAUSE ANALYSISº in LC section.
DTC 0208 OVER HEATYD25DDTi
Diagnostic Procedure (Cont'd)
EC-3500

3. Remove reservoir tank, drain coolant, then clean reservoir
tank.
+Be careful not to allow coolant to contact drive belts.
4. Remove drain plug of cylinder block.
5. Check drained coolant for contaminants such as rust, corro-
sion or discoloration. If contaminated flush engine cooling
system, refer to MA-3016, ªFLUSHING COOLING SYS-
TEMº.
Ð REFILLING ENGINE COOLANT Ð
1. Install reservoir tank, radiator drain plug and cylinder block
drain plug.
+Apply sealant to the thread of cylinder block drain plugs.
:8-11Nzm (0.8 - 1.2 kg-m, 70 - 104 in-lb)
2. Fill radiator with coolant to the filler neck of the radiator cap
at a rate of 2!(1-3/4 Imp qt)/min or lower.
+Use genuine Nissan Anti-freeze Coolant or equivalent
mixed with water (distilled or demineralized).
Refer to MA-3008, ªRECOMMENDED FLUIDS AND LUBRI-
CANTSº.
CAUTION:
If the filling rate is too fast, this could lead to air being mixed
in the coolant. Be sure to fill the coolant slowly according
to the rate indicated above.
Engine coolant capacity (With reservoir tank):
8.6!(7-5/8 Imp qt)
Reservoir tank capacity:
0.7!(5/8 Imp qt)
3. Fill reservoir tank to the MAX level.
4. Warm up engine to normal operating temperature without
radiator cap installed.
+If coolant overflows radiator filler hole, install radiator
cap.
5. Run engine at 3,000 rpm for 10 seconds and return to idle
speed with radiator cap installed.
+Repeat two or three times.
Watch coolant temperature gauge so as not to overheat the
engine.
6. Stop engine and cool it down.
+Cool down using a fan to reduce the time.
+If necessary, refill radiator up to filler neck with coolant.
7. Refill reservoir tank to MAX level line with coolant.
8. Repeat steps 4 through 7 two or more times with radiator cap
installed until coolant level no longer drops.
9. Check cooling system for leaks with engine running.
SMA162D
SMA182B Radiator
SMA412B
ENGINE MAINTENANCEYD25DDTi
Changing Engine Coolant (Cont'd)
MA-3015

ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION
LC
MODIFICATION NOTICE:
+KA24DE engine information has been added. For specifications other than those described here, refer
to D22 Supplement-II Service Manual (SM9E-D22BE0E).
+YD25DDTi engine model has been added.
CONTENTS
KA24DE
ENGINE ROOM FAN MOTOR ELECTRICAL
CIRCUIT............................................................... 3002
Wiring Diagram ................................................ 3002
YD25DDTi
ENGINE LUBRICATION SYSTEM...................... 3003
Lubricating Circuit ............................................ 3003
Oil Pressure Check .......................................... 3004
Oil Pump .......................................................... 3004
Oil Filter Bracket .............................................. 3006
Oil Cooler ......................................................... 3006
ENGINE COOLING SYSTEM.............................. 3008Overheating Cause Analysis ........................... 3008
Cooling Circuit.................................................. 3010
System Check .................................................. 3011
Water Pump ..................................................... 3012
Thermostat and Water Piping .......................... 3014
Radiator............................................................ 3015
Cooling Fan (Crankshaft driven)...................... 3016
Cooling Fan (Motor driven) .............................. 3016
SERVICE DATA AND SPECIFICATIONS
(SDS).................................................................... 3018
Engine Lubrication System .............................. 3018
Engine Cooling System ................................... 3018

LC

Overheating Cause Analysis
TROUBLESHOOTING CHART
Symptom Check items
Cooling system parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
Ð Thermostat stuck closed Ð
Damaged finsDust contamination or
paper clogging
Mechanical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not
operate
ÐÐ High resistance to fan
rotation
Damaged fan blades
Damaged radiator
shroudÐÐÐ
Improper coolant mixture
ratioÐÐÐ
Poor coolant quality Ð Ð Ð
Insufficient coolantCoolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, dete-
rioration or improper fit-
ting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir
tankExhaust gas leaks into
cooling systemCylinder head deteriora-
tion
Cylinder head gasket
deterioration
ENGINE COOLING SYSTEMYD25DDTi
LC-3008

Symptom Check items
Except cooling system
parts malfunctionÐ Overload on engineAbusive drivingHigh engine rpm under
no load
Driving in low gear for
extended time
Driving at extremely high
speed
Power train system mal-
function
Ð Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper Ð
Ð Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator Ð
Blocked condenser
Ð
Installed large fog lamp
ENGINE COOLING SYSTEMYD25DDTi
Overheating Cause Analysis (Cont'd)
LC-3009

COOLING FAN CONTROL SYSTEM
Cooling fan is controlled by ECM. For details, refer to EC section,
ªDTC 0208 OVERHEATº.
ENGINE COOLING SYSTEMYD25DDTi
Cooling Fan (Motor driven) (Cont'd)
LC-3017