2003 NISSAN X-TRAIL water pump

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
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SECTION
A
CO
ENGINE COOLING SYSTEM
QR20DE
PRECAUTIONS .......................................................... 3
Precautions For Liquid Gasket ................................. 3
REMOVAL OF LIQUID GASKET .......................... 3
LIQUID GASKET APPLICATION PROCEDURE..... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
OVERHEATING CAUSE ANALYSIS .......................... 5
Troubleshooting Chart .............................................. 5
COOLING SYSTEM .................................................... 7
Cooling Circuit .......................................................... 7
ENGINE COOLANT .................................................... 9
Inspection ................................................................. 9
LEVEL CHECK ..................................................... 9
LEAK CHECK ....................................................... 9
Changing Engine Coolant ........................................ 9
DRAINING ENGINE COOLANT ........................... 9
REFILLING ENGINE COOLANT ........................ 10
FLUSHING COOLING SYSTEM ......................... 10
RADIATOR ................................................................ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Disassembly and Assembly Radiator Fan ............. 13
DISASSEMBLY ................................................... 13
ASSEMBLY ......................................................... 13
INSPECTION ......................................................... 13
CHECKING RADIATOR CAP .............................. 13
CHECKING RADIATOR ...................................... 14
RADIATOR (ALUMINUM TYPE) .............................. 15
Disassembly and Assembly ................................... 15
PREPARATION ................................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 16
INSPECTION ...................................................... 18WATER PUMP .......................................................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 20
INSTALLATION ................................................... 20
INSPECTION AFTER INSTALLATION ................ 20
THERMOSTAT AND WATER CONTROL VALVE .... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 23
Capacity .................................................................. 23
Thermostat ............................................................. 23
Water Control Valve ................................................ 23
Radiator .................................................................. 23
Tightening Torque ................................................... 23
YD22DDTi
PRECAUTIONS ........................................................ 24
Precautions For Liquid Gasket ............................... 24
REMOVAL AND LIQUID GASKET ...................... 24
LIQUID GASKET APPLICATION PROCEDURE... 24
PREPARATION ......................................................... 25
Special Service Tools ............................................. 25
OVERHEATING CAUSE ANALYSIS ........................ 26
Troubleshooting Chart ............................................ 26
COOLING SYSTEM .................................................. 28
Cooling Circuit ........................................................ 28
ENGINE COOLANT .................................................. 30
Inspection ............................................................... 30
LEVEL CHECK .................................................... 30
LEAK CHECK ...................................................... 30
Changing Engine Coolant ....................................... 30
DRAINING ENGINE COOLANT .......................... 30
REFILLING ENGINE COOLANT ......................... 31
FLUSHING COOLING SYSTEM ......................... 32
RADIATOR ................................................................ 33
Removal and Installation ........................................ 33

CO-2
REMOVAL ........................................................... 33
INSTALLATION .................................................... 33
Disassembly and Assembly Radiator Fan .............. 34
DISASSEMBLY ................................................... 34
ASSEMBLY ......................................................... 34
Checking Radiator Cap .......................................... 34
Checking Radiator .................................................. 35
RADIATOR (ALLUMINUM TYPE) ............................. 36
Disassembly and Assembly .................................... 36
PREPARATION ................................................... 36
DISASSEMBLY ................................................... 36
ASSEMBLY ......................................................... 37
INSPECTION ....................................................... 39WATER PUMP ...........................................................40
Removal and Installation .........................................40
REMOVAL ............................................................40
INSPECTION AFTER REMOVAL ........................40
INSTALLATION ....................................................40
INSPECTION AFTER INSTALLATION ................41
THERMOSTAT AND WATER PIPING .......................42
Removal and Installation .........................................42
REMOVAL ............................................................42
INSPECTION AFTER REMOVAL ........................43
INSTALLATION ....................................................43
SERVICE DATA AND SPECIFICATIONS (SDS) ......44
Standard and Limit ..................................................44
CAPACITY ...........................................................44
THERMOSTAT .....................................................44
RADIATOR ...........................................................44
Tightening Torque ...................................................44

OVERHEATING CAUSE ANALYSIS
CO-5
[QR20DE]
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MA
CO
OVERHEATING CAUSE ANALYSISPFP:00012
Troubleshooting ChartEBS009SB
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat stuck closed —
Damaged finsDust contamination or
paper clogging
Mechanical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
—— High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper coolant mixture
ratio———
Poor coolant quality — — —
Insufficient coolantCoolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into
cooling systemCylinder head deterioration
Cylinder head gasket dete-
rioration

WATER PUMP
CO-19
[QR20DE]
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CO
WATER P UM PPFP:21020
Removal and InstallationEBS009SJ
WA RN ING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
REMOVAL
Water Pump Removal
1. Drain coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
CAUTION:
Perform when the engine is cold.
2. Remove the following parts.
lEngine under cover
lAlternator, water pump and air compressor belt
Refer to drive beltEM-13, "
Removal and Installation".
3. Remove water pump.
lCoolant will leak from the cylinder block, so have a receptacle ready below.
CAUTION:
lHandle the water pump vane so that it does not contact any other parts.
lWater pump cannot be disassembled and should be replaced as a unit.
Water Pump Housing Removal
1. Perform step 1 and 2 of “Water Pump Removal”.
2. Remove alternator.
3. Remove oil level gauge.
CAUTION:
Plug the oil level gauge guide opening to prevent oil pan from entering foreign materials.
4. Remove bolts mounting water pipe.
5. Remove water pump housing.
Water Pipe Removal
1. Remove water pump housing.
KBIA0154E
1 Water pump 2 Gasket 3 Water pump housing
4 Water pipe

CO-20
[QR20DE]
WATER PUMP
2. Remove exhaust manifold and three way catalyst assembly. Refer toEM-22, "EXHAUST MANIFOLD
AND THREE WAY CATALYST".
3. Remove water pipe.
INSPECTION AFTER REMOVAL
lVisually check that there is no significant dirt or rusting on the
water pump body and vane.
lCheck that there is no looseness in the vane shaft, and that it
turns smoothly when rotated by hand.
lIf there are any unusualness, replace the water pump assembly.
INSTALLATION
lInstall in the reverse order of removal
lWhen inserting water pipe end to cylinder block, apply a neutral detergent to o-ring. Then insert it immedi-
ately.
INSPECTION AFTER INSTALLATION
lCheck for coolant leaks using radiator cap tester. Refer toCO-9, "LEAK CHECK".
KBIA0155E

SERVICE DATA AND SPECIFICATIONS (SDS)
CO-23
[QR20DE]
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
CapacityEBS009SL
ThermostatEBS009SM
Water Control ValveEBS009SN
RadiatorEBS009SO
Unit:kPa(bar,kg/cm2,psi)
Tightening TorqueEBS009SP
Unit: N·m (kg-m, ft-lb) Nm(kg-m, in-lb)* Coolant capacity [With reservoir tank (MAX level)]
Approximately 7.1 (6-1/4 Imp qt)
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Valve liftMore than 8 mm/ 95°C (0.315 in/203°F)
Valve opening temperature 93.5 - 96.5°C (200 - 206°F)
Valve lift More than 8 mm/108°C (0.315 in/226°F)
Cap relief pressureStandard 78 - 98 (0.78 - 0.98, 0.8 -1.0, 11- 14)
Limit 59 (0.59, 0.6, 9)
Leakage test pressure 157 (1.57, 1.6, 23)
Radiator mounting bracket
Radiator fan assembly
Fan
Fan motor3.8 - 4.5 (0.39 - 0.46, 34 - 39)*
3.8 - 4.5 (0.39 - 0.46, 34 - 39)*
2.9 - 3.9 (0.30 - 0.40, 26 - 34)*
3.9 - 4.9 (0.40 - 0.50, 35 - 43)*
Water pum p
Water pump housing
Water inlet
Water outlet
Water pipet
Hater pip
Water temperature sensor20.8 - 28.2 (2.1 - 2.9, 16- 20)
20.8 - 28.2 (2.1 - 2.9, 16 - 20)
20.8 - 28.2 (2.1 - 2.9, 16- 20)
20.8 - 28.2 (2.1 - 2.9, 16 - 20)
20.8 - 28.2 (2.1 - 2.9, 16 - 20)
20.8 - 28.2 (2.1 - 2.9, 16 - 20)
19.6 - 29.4 (2.0 - 3.0, 14- 22)

CO-26
[YD22DDTi]
OVERHEATING CAUSE ANALYSIS
OVERHEATING CAUSE ANALYSIS
PFP:00012
Troubleshooting ChartEBS00BAW
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat stuck closed —
Damaged finsDust contamination or
paper clogging
Mechanical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
—— High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper coolant mixture
ratio———
Poor coolant quality — — —
Insufficient coolantCoolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank
Overflowing reservoir tankExhaust gas leaks into
cooling systemCylinder head deterioration
Cylinder head gasket dete-
rioration

CO-40
[YD22DDTi]
WATER PUMP
WAT ER PU M P
PFP:21020
Removal and InstallationEBS00BB4
WAR NIN G:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
REMOVAL
1. Remove the under cover, splash cover (right), and drive belt.
2. Drain engine coolant. Refer toCO-30, "
DRAINING ENGINE COOLANT".
CAUTION:
Perform when the engine is cold.
3. Support the bottom of the oil pan with a floor jack etc, and remove the right engine mount bracket (front
side of the engine).
4. Remove the water pump pulley.
lLoosen the pulley bolts after fixing the pulley using a screwdriver etc.
5. Remove engine mount bracket.
6. Remove the water pump.
lCoolant will leak from the cylinder block, so have a receptacle ready below.
CAUTION:
lHandle the water pump vane so that it does not contact any other parts.
lWater pump cannot be disassembled and should be replaced as a unit.
INSPECTION AFTER REMOVAL
lVisually check that there is no significant dirt or rusting on the
water pump body and vane.
lCheck that there is no looseness in the vane shaft, and that it
turns smoothly when rotated by hand.
lIf there are any unusualness, replace the water pump assembly.
INSTALLATION
lInstall in the reverse order of removal
JLC294B
SBIA0132E