WATER PUMP
CO-27
[VQ35DE]
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Revision: 2006 January2006 M35/M45
a. Turn crankshaft pulley clockwise so that timing chain on the tim-
ing chain tensioner (primary) side is loose.
b. Pull plunger stopper tab up (or turn lever downward) so as to
remove plunger stopper tab from the ratchet of plunger.
NOTE:
Plunger stopper tab and lever are synchronized.
c. Push plunger into the inside of tensioner body.
d. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet.
e. To secure lever, insert stopper pin through hole of lever into ten-
sioner body hole.
The lever parts and the tab are synchronized. Therefore, the
plunger will be secured under this condition.
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
f. Install timing chain tensioner (primary).
Remove dust and foreign material completely from backside of timing chain tensioner (primary) and
from installation area of rear timing chain case.
g. Remove stopper pin.
h. Make sure again that timing chain and water pump sprocket are engaged.
4. Install chain tensioner cover and water pump cover as follows:
a. Before installing, remove all traces of old liquid gasket from mat-
ing surface of water pump cover and chain tensioner cover
using scraper. Also remove traces of old liquid gasket from the
mating surface of front timing chain case.
PBIC1805E
PBIC3568E
PBIC3577E
SLC446B
CO-32
[VQ35DE]
WATER OUTLET AND WATER PIPING
Revision: 2006 January2006 M35/M45
9. Remove heater pipe, water bypass hoses and water pipe.
INSTALLATION
Note the following, and install in the reverse order of removal.
Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.
When inserting water pipe into water outlet, apply neutral detergent to O-ring.
INSPECTION AFTER INSTALLATION
Check for leaks of engine coolant using the radiator cap tester adapter [SST: EG17650301 (J33984-A)]
and the radiator cap tester (commercial service tool). Refer to CO-11, "
LEAK CHECK" .
Start and warm up the engine. Visually make sure that there is no leaks of engine coolant.
CO-44
[VK45DE]
RADIATOR
Revision: 2006 January2006 M35/M45
CAUTION:
Perform this step when the engine is cold.
Do not spill engine coolant on drive belts.
4. Remove the A/C piping bracket from left side member, and then move the A/C piping out of the way.
5. Disconnect A/T fluid cooler hoses from radiator.
Install blind plug to avoid leakage of A/T fluid.
6. Remove radiator hoses (upper and lower) and reservoir tank hose.
CAUTION:
Be careful not to allow engine coolant to contact drive belts.
7. Remove cooling fan assembly (1). Refer to CO-51, "
COOLING
FA N" .
CAUTION:
Do not damage or scratch radiator core when removing.
8. Remove radiator as follows:
a. Remove mount bracket (RH and LH).
b. Pull the radiator (1) rearward from the vehicle, and then remove
the mounting bolts (3) and A/C condenser (2).
NOTE:
Figure shows right side.
c. Lift up and pull the radiator (4) rearward, and then remove the mounting rubber (lower) (3) from the radia-
tor core support (2).
CAUTION:
At this time, A/C condenser is on the lower end of radiator
front surface. Minimize the movement to the rear side.
d. Lift up the A/C condenser to disengage the lower end of front surface, and then remove the radiator.
CAUTION:
Be careful not to damage radiator and A/C condenser core.
Minimize the lift of A/C condenser to prevent load from being applied to A/C piping.
e. After removing the radiator, place the A/C condenser on the radiator core support to prevent load from
being applied to piping. And then, temporarily secure them using a rope to prevent them from being
dropped.
KBIA3587J
KBIA3586J
1 : A/C condenser
: Engine front
PBIC3389E
CO-50
[VK45DE]
RADIATOR (ALUMINUM TYPE)
Revision: 2006 January2006 M35/M45
4. Make sure that the rim is completely crimped down.
5. Make sure that there is no leakage. Refer to CO-50, "
INSPECTION" .
INSPECTION
1. Apply pressure with radiator cap tester adapter (SST) and radia-
tor cap tester (commercial service tool).
provide used radiator and connect it to tested radiator using
radiator hoses as shown in the figure.
NOTE:
The used radiator should be tested beforehand to confirm it
has no leakage. If used one is not available, it is possible to
use new service part as a radiator testing tool.
WA R N I N G :
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.
2. Check for leakage by soaking radiator in water container with
the testing pressure applied.Standard height “H” : 8.0 - 8.4 mm (0.315 - 0.331 in)
SLC554A
Testing pressure
: 157 kPa (1.6 kg/cm
2 , 23 psi)PBIC1658E
PBIC1699E
CO-52
[VK45DE]
COOLING FAN
Revision: 2006 January2006 M35/M45
NOTE:
Cooling fans are controlled by cooling fan control module. For details. Refer to EC-1239, "
DTC P1217
ENGINE OVER TEMPERATURE" .
Disassembly and Assembly NBS004RO
DISASSEMBLY
1. Disconnect sub-harness from fan motor (RH and LH) and cooling fan control module.
2. Remove cooling fan control module from fan shroud.
CAUTION:
Handle carefully to avoid dropping and shocks.
3. Remove cooling fan mounting nuts, and then remove the cooling fan (RH and LH).
4. Remove fan motor (RH and LH).
INSPECTION AFTER DISASSEMBLY
Cooling Fan
Inspect cooling fan for crack or unusual bend.
If anything is found, replace cooling fan.
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
CAUTION:
RH and LH cooling fans are different. Be careful not to misassemble them.
Install each fan in the following position.
Secure the sub-harness tightly to the fan shroud to prevent the fan rotation area from being loose. Right side : 4 fans
Left side : 5 fans
WATER PUMP
CO-53
[VK45DE]
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WAT E R PU M PPFP:21020
ComponentsNBS004RP
Refer to GI-11, "Components" for symbol marks in the figure.
Removal and InstallationNBS004RQ
CAUTION:
When removing water pump, be careful not to get engine coolant on drive belts.
Water pump can not 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 (commercial service tool) and radiator cap tester adapter [SST: EG17650301 (J33984-
A)].
REMOVAL
1. Remove following parts:
Front engine undercover (power tool)
Engine cover: Refer to EM-179, "INTAKE MANIFOLD" .
Engine room cover (RH and LH): Refer to EM-173, "ENGINE ROOM COVER" .
Air duct (inlet): Refer to EM-177, "AIR CLEANER AND AIR DUCT" .
Alternator, water pump and A/C compressor belt: Refer to EM-174, "DRIVE BELTS" .
2. Drain engine coolant from drain plugs on radiator and both side of cylinder block. Refer to CO-40, "
Chang-
ing Engine Coolant" and EM-250, "DISASSEMBLY" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
3. Remove water pump pulley.
4. Remove water pump.
Engine coolant will leak from cylinder block, so have a receptacle ready under vehicle.
CAUTION:
Handle the water pump vane so that it does not contact any other parts.
Do not disassemble water pump.
1. Water pump 2. Water pump pulley 3. Gasket
PBIC3396E
CO-56
[VK45DE]
THERMOSTAT AND WATER CONTROL VALVE
Revision: 2006 January2006 M35/M45
5. Disconnect water suction hose from water inlet.
6. Remove water inlet and thermostat.
CAUTION:
Do not disassemble thermostat.
7. Remove intake manifolds (upper and lower). Refer to EM-179, "
INTAKE MANIFOLD" .
8. Disconnect radiator hose (upper) from thermostat housing.
9. Disconnect heater hoses from water outlet and heater pipe.
10. Remove thermostat housing, water outlet pipe, water connector, water control valve, water outlet and
heater pipe.
CAUTION:
Do not disassemble water control valve.
INSPECTION AFTER REMOVAL
Make sure that valves both in thermostat and water control valve are completely closing at normal tempar-
ature.
Place a thread so that it is caught in the valves of the thermostat
and water control valve. Immerse fully in a container filled with
water. Heat while stirring. (The example in the figure shows ther-
mostat.)
The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
Continue heating. Check the maximum valve lift.
NOTE:
The maximum valve lift standard temperature for water control
valve is the reference value.
After checking the maximum valve lift, lower the water tempera-
ture and check the valve closing temperature.
Standard values:
If the malfunctioning condition, when closing valve at normal temperature, or measured values are out of
the standard, replace thermostat and/or water control valve.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Be careful not to spill engine coolant over engine room. Use rag to absorb engine coolant.
Thermostat and Water Control Valve
Install thermostat and water control valve with the whole circum-
ference of each flange part fit securely inside rubber ring. (The
example in the figure shows thermostat.)
SLC252B
Thermostat Water control valve
Valve opening temperature 80 - 84
C (176 - 183F) 93.5 - 96.5C (200 - 206F)
Maximum valve liftMore than 10 mm/ 95
C
(0.39 in/ 203
F)More than 8 mm/ 108
C
(0.315 in/ 226
F)
Valve closing temperature 77
C (171F) 90C (194F)
PBIC0157E
LANE DEPARTURE WARNING SYSTEM
DI-91
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Terminals and Reference Value for LDW Camera UnitNKS003VL
NOTE:
*: Perform “ACTIVE TEST” with CONSULT-II. Refer to DI-94, "
ACTIVE TEST" .
CONSULT-II Function (LDW)NKS003VM
DESCRIPTION
CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.
CONSULT-II BASIC OPERATION
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
1. With the ignition switch OFF, connect CONSULT-II and CON-
SULT-II CONVERTER to the data link connector, and then turn
ignition switch ON.
Terminal
No.Wire
colorItemCondition
Reference value
(Approx.) Ignition
switchOperation or condition
1 B/R Ignition switch ON or START ON — Battery voltage
3R/WLDW chime ONLDW chimeActivated
*0 V
Not activated 12 V
4 V System ON indicator ON LDW systemON 0 V
OFF 12 V
5 P CAN L — — —
6 B Ground ON — 0 V
8 G/W LDW indicator lamp ON LDW indicator lamp Illuminated
*0 V
Turned OFF 12 V
9 GR LDW switch ON LDW switchPushed 0 V
Released 5 V
10 L CAN H — — —
12 B Ground ON — 0 V
System Diagnosis mode DescriptionReference
page
LDWWORK SUPPORT Displays causes of automatic cancellation of the LDW system.DI-92
SELF-DIAG RESULTS Displays malfunctioning system memorized in LDW camera unit.DI-92
DATA MONITOR Displays real-time input/output data of LDW camera unit.DI-93
CAN DIAG SUPPORT MNTR Displays the results of transmit/receive diagnosis of CAN communication.LAN-7
ACTIVE TEST Enables operation check of electrical loads by sending driving signal to them.DI-94
ECU PART NUMBER Displays part number of LDW camera unit. —
SKIB3794E