water pump INFINITI FX35 2004 Service Manual

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
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SECTION CO
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Revision: 2004 November 2004 FX35/FX45
ENGINE COOLING SYSTEM
VQ35DE
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for Liquid Gasket .................................. 3
REMOVAL OF LIQUID GASKET SEALING .......... 3
LIQUID GASKET APPLICATION PROCEDURE ..... 3
PREPARATION ........................................................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 6
OVERHEATING CAUSE ANALYSIS .......................... 7
Troubleshooting Chart .............................................. 7
COOLING SYSTEM .................................................... 9
Cooling Circuit .......................................................... 9
System Drawing ..................................................... 10
ENGINE COOLANT ...................................................11
Inspection ................................................................ 11
LEVEL CHECK .................................................... 11
CHECKING COOLING SYSTEM FOR LEAKS .... 11
Changing Engine Coolant ....................................... 11
DRAINING ENGINE COOLANT .......................... 11
REFILLING ENGINE COOLANT ........................ 12
FLUSHING COOLING SYSTEM ......................... 13
RADIATOR ................................................................ 14
Removal and Installation ........................................ 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
INSPECTION AFTER INSTALLATION ............... 15
Checking Radiator Cap .......................................... 15
Checking Radiator .................................................. 16
RADIATOR (ALUMINUM TYPE) .............................. 17
Disassembly and Assembly ................................... 17
PREPARATION ................................................... 17
DISASSEMBLY ................................................... 17
ASSEMBLY ......................................................... 18
INSPECTION ...................................................... 20
COOLING FAN ......................................................... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21INSTALLATION ................................................... 21
Disassembly and Assembly .................................... 21
DISASSEMBLY ................................................... 21
ASSEMBLY ......................................................... 21
WATER PUMP .......................................................... 22
Removal and Installation ........................................ 22
REMOVAL ........................................................... 22
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 25
WATER INLET AND THERMOSTAT ASSEMBLY .... 26
Removal and Installation ........................................ 26
REMOVAL ........................................................... 26
INSPECTION AFTER REMOVAL ....................... 27
INSTALLATION ................................................... 27
INSPECTION AFTER INSTALLATION ................ 27
WATER OUTLET AND WATER PIPING ................... 28
Removal and Installation ........................................ 28
REMOVAL ........................................................... 28
INSTALLATION ................................................... 28
INSPECTION AFTER INSTALLATION ................ 28
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 29
Standard and Limit .................................................. 29
ENGINE COOLANT CAPACITY (APPROXI-
MATE) .................................................................. 29
THERMOSTAT .................................................... 29
RADIATOR .......................................................... 29
VK45DE
PRECAUTIONS ........................................................ 30
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ................................................................. 30
PREPARATION ......................................................... 31
Special Service Tools ............................................. 31
Commercial Service Tools ...................................... 31
OVERHEATING CAUSE ANALYSIS ........................ 32
Troubleshooting Chart ............................................ 32

CO-2Revision: 2004 November 2004 FX35/FX45 COOLING SYSTEM .................................................. 34
Cooling Circuit ........................................................ 34
System Drawing ..................................................... 35
ENGINE COOLANT .................................................. 36
Inspection ............................................................... 36
LEVEL CHECK .................................................... 36
LEAK CHECK ...................................................... 36
Changing Engine Coolant ....................................... 36
DRAINING ENGINE COOLANT .......................... 36
REFILLING ENGINE COOLANT ......................... 37
FLUSHING COOLING SYSTEM ......................... 38
RADIATOR ................................................................ 39
Removal and Installation ........................................ 39
REMOVAL ........................................................... 39
INSTALLATION .................................................... 41
INSPECTION AFTER INSTALLATION ................ 41
Checking Radiator Cap .......................................... 41
Checking Radiator .................................................. 41
RADIATOR (ALUMINUM TYPE) ............................... 43
Disassembly and Assembly .................................... 43
PREPARATION ................................................... 43
DISASSEMBLY ................................................... 43
ASSEMBLY ......................................................... 44
INSPECTION ....................................................... 46
COOLING FAN .......................................................... 47
Removal and Installation (Crankshaft Driven Type) ... 47
REMOVAL ........................................................... 47
INSPECTION AFTER REMOVAL ........................ 47INSTALLATION .................................................... 47
Removal and Installation (Motor Driven Type) ........ 48
REMOVAL ............................................................ 48
INSTALLATION .................................................... 48
Disassembly and Assembly (Motor Driven Type) ... 48
DISASSEMBLY .................................................... 48
INSPECTION AFTER DISASSEMBLY ................ 48
ASSEMBLY .......................................................... 48
WATER PUMP ........................................................... 49
Removal and Installation ......................................... 49
REMOVAL ............................................................ 49
INSPECTION AFTER REMOVAL ........................ 49
INSTALLATION .................................................... 50
INSPECTION AFTER INSTALLATION ................ 50
THERMOSTAT AND WATER CONTROL VALVE ..... 51
Removal and Installation ......................................... 51
REMOVAL ............................................................ 51
INSPECTION AFTER REMOVAL ........................ 52
INSTALLATION .................................................... 52
INSPECTION AFTER INSTALLATION ................ 53
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 54
Standard and Limit .................................................. 54
ENGINE COOLANT CAPACITY (APPROXI-
MATE) .................................................................. 54
RADIATOR ........................................................... 54
THERMOSTAT ..................................................... 54
WATER CONTROL VALVE .................................. 54

PREPARATION
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[VQ35DE]
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Revision: 2004 November 2004 FX35/FX45
PREPARATIONPFP:00002
Special Service ToolsABS004T4
The actual shapes of Kent-Moore tools may from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool nameDescription
WS39930000
( – )
Tube presserPressing tube of liquid gasket
KV10111100
(J-37228)
Seal cutterRemoving chain tensioner cover and water
pump cover
EG17650301
(J-33984-A)
Radiator cap tester adapterAdapting radiator cap tester to radiator cap
and 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 AInstalling radiator upper and lower tanks
KV99103520
( – )
Radiator plate pliers BRemoving radiator upper and lower tanks
S-NT052
NT046
S-NT564
S-NT224
S-NT225

OVERHEATING CAUSE ANALYSIS
CO-7
[VQ35DE]
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Revision: 2004 November 2004 FX35/FX45
OVERHEATING CAUSE ANALYSISPFP:00012
Troubleshooting ChartABS004UZ
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
Physical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
Fan assembly — High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper engine coolant
mixture ratio—— —
Poor engine coolant quality — Engine coolant density —
Insufficient engine coolantEngine coolant 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-22
[VQ35DE]
WATER PUMP
Revision: 2004 November 2004 FX35/FX45
WATE R P U M PPFP:21020
Removal and InstallationABS009RE
CAUTION:

When removing water pump, be careful not to get engine coolant on drive belt.

Water pump cannot be disassembled and should be replaced as a unit.
REMOVAL
1. Remove front engine undercover with power tool.
2. Remove drive belts. Refer to EM-15, "
DRIVE BELTS" .
3. Drain engine coolant from radiator. Refer to CO-11, "
Changing Engine Coolant" .
CAUTION:
Perform when engine is cold.
4. Remove air duct (inlet), power duct and air cleaner case assembly. Refer to EM-17, "
AIR CLEANER AND
AIR DUCT" .
5. Remove water drain plug (front) of cylinder block.
6. Remove chain tensioner cover and water pump cover separat-
i n g t h e m a t i n g s u r f a c e w i t h a s e a l c u t t e r [ S S T: K V 1 0 1111 0 0 ( J -
37228)].
CAUTION:
Be careful not to damage the mating surfaces.
1. Chain tensioner 2. Chain tensioner cover 3. Water pump cover
4. Water pump 5. O-rings 6. Water drain plug (front)
SBIA0482E
PBIC0846E

WATER PUMP
CO-23
[VQ35DE]
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Revision: 2004 November 2004 FX35/FX45
7. Remove timing chain tensioner (primary) with the following pro-
cedure.
a. Pull the lever down and release plunger stopper tab.

Plunger stopper tab can be pushed up to release (coaxial
structure with lever).
b. Insert stopper pin into the tensioner body hole to hold lever and
keep the plunger stopper tab released.
NOTE:
An Allen wrench [2.5 mm (0.098 in)] is used for a stopper pin as
an example.
c. Insert plunger into the tensioner body by pressing timing chain
slack guide.
d. Keep slack guide pressed and hold plunger in by pushing stopper pin deeper through lever and into the
tensioner body hole.
e. Turn crankshaft pulley approximately 20° clockwise so that tim-
ing chain on the timing chain tensioner (primary) side is loose.
f. Remove mounting bolts and timing chain tensioner (primary).
CAUTION:
Be careful not to drop mounting bolts inside chain case.
8. Remove three water pump fixing bolts. Secure a gap between
water pump gear and timing chain, by turning crankshaft pulley
counterclockwise until timing chain looseness on water pump
sprocket becomes maximum.
PBIC2112E
PBIC0848E
PBIC2113E
PBIC1193E

CO-24
[VQ35DE]
WATER PUMP
Revision: 2004 November 2004 FX35/FX45
9. 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
holes until they reach timing chain case. Then, alternately
tighten each bolt for a half turn, and pull out water pump.
CAUTION:

Pull straight out while preventing vane from contacting
socket in installation area.

Remove water pump without causing sprocket to contact
timing chain.
10. Remove M8 bolts and O-rings from water pump.
CAUTION:
Do not disassembly water pump.
INSPECTION AFTER REMOVAL

Check for badly rusted or corroded water pump body assembly.

Check for rough operation due to excessive end play.

If anything is found, replace water pump.
INSTALLATION
1. Install new O-rings to water pump.

Apply engine oil and engine coolant to O-rings as shown in
the figure.

Locate O-ring with white paint mark to engine front side.
2. Install water pump.
CAUTION:
Do not allow cylinder block to nip O-rings when install
water pump.

Make sure timing chain and water pump sprocket are
engaged.

Insert water pump by tightening mounting bolts alternately
and evenly.
3. Install timing chain tensioner (primary) as the following:
a. Remove dust and foreign material completely from backside of chain tensioner and from installation area
of rear timing chain case.
b. Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose.

Apply engine oil should be applied to the oil hole and tensioner, when installing timing chain
tensioner.
JLC357B
SLC943A
PBIC1397E
PBIC1058E

WATER PUMP
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Revision: 2004 November 2004 FX35/FX45
c. Install timing chain tensioner (primary).
d. Remove stopper pin.
4. Install chain tensioner cover and water pump cover.
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 front timing chain case.
b. Apply a continuous bead of liquid gasket to mating surface of
chain tensioner cover and water pump cover with tube presser
[SST: WS39930000 ( – )].
Use Genuine RTV Silicone Sealant or equivalent. GI-48,
"RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS".
5. Install water drain plug (front) of cylinder block.

Apply liquid gasket to the thread of water drain plug (front).
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "
RECOMMENDED CHEMICAL
PRODUCTS AND SEALANTS".
6. Install in the reverse order of removal for remaining parts.

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 chain tensioner. Engine may produce a rattling
noise. This indicates that air still remains in the chamber and is not a matter of concern.
INSPECTION AFTER INSTALLATION

Check for leaks of engine coolant using radiator cap tester adapter [SST: EG17650301 (J-33984-A)] and
radiator cap tester (commercial service tool). Refer to CO-11, "
CHECKING COOLING SYSTEM FOR
LEAKS" .

Start and warm up engine. Visually make sure that there is no leaks of engine coolant and A/T fluid.
SLC448B
SLC446B
PBIC1283E

CO-32
[VK45DE]
OVERHEATING CAUSE ANALYSIS
Revision: 2004 November 2004 FX35/FX45
OVERHEATING CAUSE ANALYSISPFP:00012
Troubleshooting ChartABS006JF
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
Physical damage
Clogged radiator cooling
tubeExcess foreign material
(rust, dirt, sand, etc.)
Reduced air flowCooling fan does not oper-
ate
Fan assembly — High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper engine coolant
mixture ratio—— —
Poor engine coolant quality — Engine coolant density —
Insufficient engine coolantEngine coolant 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

COOLING FAN
CO-47
[VK45DE]
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Revision: 2004 November 2004 FX35/FX45
COOLING FANPFP:21140
Removal and Installation (Crankshaft Driven Type)ABS006JT
REMOVAL
1. Remove air duct (inlet). Refer to EM-172, "AIR CLEANER AND AIR DUCT" .
2. Remove engine front undercover with power tool.
3. Remove radiator shroud (lower). Refer to CO-39, "
Removal and Installation" .
4. Remove drive belts. Refer to EM-169, "
DRIVE BELTS" .
5. Remove cooling fan.
CAUTION:
Do not damage or scratch radiator core when removing.
INSPECTION AFTER REMOVAL
Fan Coupling
Inspect fan coupling for oil leakage and bimetal conditions.

If anything is found, replace fan coupling.
Cooling Fan
Inspect cooling fan for crack or unusual bend.

If anything is found, replace cooling fan.
INSTALLATION
Note to the following, install in the reverse order of removal.

Install cooling fan with its front mark “F” facing front of vehicle. Refer to CO-47, "Removal and Installation
(Crankshaft Driven Type)" .
1. Cooling fan 2. Fan coupling 3. Fan pulley
4. Water pump
PBIC1537E
SLC072