2003 NISSAN ALMERA N16 iat

Symptom Check items
Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system malfunc-
tion
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
—
Installed large fog lamp
Service Data and Specifications (SDS)
THERMOSTATNJLC0029
Valve opening temperature °C (°F) 82 (180)
Valve lift mm/°C (in/°F)More than 8/95 (0.31/203)
RADIATORNJLC0030Unit: kPa (bar, kg/cm2, psi)
Cap reliefpressureStandard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Limit 59 - 98 (0.59 - 0.98, 0.6 - 1.0, 9 - 14)
Leakage test pressure157 (1.57, 1.6, 23)
COOLANT CAPACITYNJLC0038Unit:(Imp qt)
M/T*6.7 (5-7/8)
A/T*Sedan 6.6 (5-7/8)
Hatchback 6.7 (5-7/8)
Reservoir tank0.7 (5/8)
*: With reservoir tank
ENGINE COOLING SYSTEMQG
Overheating Cause Analysis (Cont’d)
LC-24

SEM164F
AEM080
Precautions
LIQUID GASKET APPLICATION PROCEDURENJLC00511. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket.)
For oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
For areas except oil pan, be sure liquid gasket diameter is 2.0
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.
Preparation
SPECIAL SERVICE TOOLSNJLC0052
Tool number
Tool nameDescription
EG17650301
Radiator cap tester
adapter
NT564
Adapting radiator cap tester to radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
KV99103510
Radiator plate pliers A
NT224
Installing radiator upper and lower tanks
KV99103520
Radiator plate pliers B
NT225
Removing radiator upper and lower tanks
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ENGINE COOLING SYSTEMYD
Precautions
LC-35

System CheckNJLC0054WARNING:
Never remove the radiator cap when the engine is hot; serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap and carefully remove it by
turning it a quarter turn to allow built-up pressure to escape
and then turn the cap all the way off.
CHECKING COOLING SYSTEM HOSESNJLC0054S01Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATORNJLC0054S02Check radiator for mud or clogging. If necessary, clean radiator as
follows.
Be careful not to bend or damage the radiator fins.
When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, radiator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1. Apply water by hose to the back side of the radiator core ver-
tically downward.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor.
4. Blow air into the back side of radiator core vertically downward.
Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm
2,71
psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.
SLC755AC
CHECKING RADIATOR CAPNJLC0054S03To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm
2, 11 - 14 psi)
Limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm
2,9-14psi)
SMA967B
Pull the negative pressure valve to open it.
Check that it closes completely when released.
Check the radiator cap negative pressure valve for contamina-
tion or damage to the valve seat.
Move the negative pressure valve to check for abnormalities to
the opening/shutting operation.
CAUTION:
Be sure to perform the inspections after cooling down the
engine.
Before connecting the radiator cap to the tester, apply
water or LLC to the cap sealing.
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ENGINE COOLING SYSTEMYD
System Check
LC-37

Replace the radiator cap if abnormalities are found with the
negative pressure valve, or if the valve opening pressure is out
of the standard range.
SLC756AA
CHECKING COOLING SYSTEM FOR LEAKSNJLC0054S04To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2,23psi)
CAUTION:
Higher than the specified pressure may cause radiator
damage.
Be sure to perform the inspections after cooling down the
engine.
Use a hose adapter between the cap tester and filler neck
to prevent the radiator filler neck from deforming.
If any abnormalities are found, repair or replace the malfunc-
tioning parts.
Water Pump
REMOVAL AND INSTALLATIONNJLC0055CAUTION:
When removing water pump assembly, be careful not to
get coolant on drive belt.
Water pump cannot be disassembled and should be
replaced as a unit.
After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
ENGINE COOLING SYSTEMYD
System Check (Cont’d)
LC-38

SLC252B
INSPECTIONNJLC00601. Check valve seating condition at ordinary room temperatures.
It should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Standard
Valve opening temperature Above 80.5 - 83.5°C (177 - 182°F)
Valve lift More than 9 mm/95°C
(0.354 in/203°F)
3. Then check if valve closes at 5°C (9°F) below valve opening
temperature.
Radiator
COMPONENTSNJLC0083
SLC430B
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ENGINE COOLING SYSTEMYD
Thermostat (Cont’d)
LC-41

REMOVAL AND INSTALLATION=NJLC00631. Remove under cover.
2. Drain coolant by removing lower radiator hose.
3. Disconnect radiator upper and lower hoses.
4. Remove radiator shroud.
5. Disconnect reservoir tank hose.
6. Remove radiator mounting bracket.
7. Remove radiator.
8. After repairing or replacing radiator, install any part removed in
reverse order of removal.
When filling radiator with coolant, refer to LC-43, “Changing
Engine Coolant”.
Cooling FanNJLC0064COMPONENTSNJLC0064S01
JLC347B
CONTROL SYSTEMNJLC0064S02Cooling fans are controlled by ECM. For details, refer to EC-130,
“DTC P1217 OVER HEAT”.
ENGINE COOLING SYSTEMYD
Radiator (Cont’d)
LC-42

JLC295B
Changing Engine CoolantNJLC0079WARNING:
To avoid the danger of being scalded, never change the cool-
ant when the engine is hot.
— DRAINING ENGINE COOLANT —NJLC0079S011. Set air conditioning system as follows to prevent coolant from
remaining in the system.
a. Turn ignition switch ON and set temperature controller to maxi-
mum hot position.
b. Wait 10 seconds before turning ignition switch OFF.
SMA033D
2. Remove lower radiator hose, and remove radiator filler cap to
drain coolant.
3. Remove reservoir tank, drain coolant, then clean reservoir
tank.
Be careful not to allow coolant to contact drive belts.
4. Cover the exhaust tube heat shield to prevent from splashing
coolant.
JLC429B
YLC026
5. Remove drain plug of cylinder block and air relief plug.
6. Check drained coolant for contaminants such as rust, corro-
sion or discoloration. If contaminated flush engine cooling
system, refer to LC-45, “FLUSHING COOLING SYSTEM”.
7. Blow the coolant around the exhaust tube heat shield.
NOTE:
An asterisk (*1) in the figure means “Not installed on some
models”.
JLC298B
— REFILLING ENGINE COOLANT —NJLC0079S021. Install reservoir tank, radiator drain cock or lower radiator hose
and cylinder block drain plug.
Apply sealant to the thread of cylinder block drain plugs.
: 8 - 11 N·m (0.8 - 1.2 kg-m, 70 - 104 in-lb)
2. Fill radiator slowly with coolant until coolant spills from the air
relief plugs, then install air relief plugs.
Location of air relief plugs
Water inlet and rear side intake manifold water tubes
3. Disconnect heater hose at engine, pour coolant into the hose
so that it flows toward the heater core.
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ENGINE COOLING SYSTEMYD
Changing Engine Coolant
LC-43

While filling, if coolant from engine side spills out, be sure to
reconnect the heater hose.
Fill coolant to the level of the radiator cap at a rate of 2(1-3/4
Imp qt)/min or lower.
(Close the air relief plugs in order starting with the location from
where the coolant began spilling out.)
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.
Replace the copper washer of the air bleeding plug.
Air relief plug:
: 6.7 - 7.9 N·m (0.68 - 0.81 kg-m, 59 - 70 in-lb)
Use genuine Nissan anti-freeze coolant or equivalent
mixed with water (distilled or demineralized).
SMA182B
SMA412B
Refer to MA-19, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Engine coolant capacity (With reservoir tank):
8.7(7-5/8 Imp qt)
Reservoir tank capacity:
0.7(5/8 Imp qt)
Pour coolant through coolant filler neck slowly to allow air
in system to escape.
4. Fill radiator and reservoir tank to specified level.
5. Warm up engine to normal operating temperature without
radiator cap installed.
If coolant overflows radiator filler hole, install radiator cap.
6. 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.
7. 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.
8. Refill reservoir tank to MAX level line with coolant.
9. Repeat steps 4 through 7 two or more times with radiator cap
installed until coolant level no longer drops.
10. Check cooling system for leaks with engine running.
11. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 3,000 rpm with heater tempera-
ture controller set at several positions between COOL and
HOT.
Sound may be noticeable at heater water cock.
12. If sound is heard, bleed air from cooling system by repeating
steps 4 through 7 until coolant level no longer drops
Clean excess coolant from engine.
ENGINE COOLING SYSTEMYD
Changing Engine Coolant (Cont’d)
LC-44