coolant level NISSAN NAVARA 2005 Repair Workshop Manual

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
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ENGINE COOLING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions For Liquid Gasket ................................. 2
LIQUID GASKET APPLICATION PROCEDURE..... 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
Commercial Service Tools ........................................ 3
OVERHEATING CAUSE ANALYSIS .......................... 4
Troubleshooting Chart .............................................. 4
COOLING SYSTEM .................................................... 6
Cooling Circuit .......................................................... 6
ENGINE COOLANT .................................................... 7
Inspection ................................................................. 7
LEVEL CHECK ..................................................... 7
CHECKING RADIATOR SYSTEM FOR LEAKS..... 7
Changing Engine Coolant ........................................ 7
DRAINING ENGINE COOLANT ........................... 8
REFILLING ENGINE COOLANT .......................... 8
FLUSHING COOLING SYSTEM ........................... 9
RADIATOR .................................................................11
Components ............................................................ 11
Removal and Installation ......................................... 11
REMOVAL ............................................................ 11
INSPECTION AFTER REMOVAL ....................... 13
INSTALLATION ................................................... 14
INSPECTION AFTER INSTALLATION ............... 14
RADIATOR (ALUMINUM TYPE) .............................. 15
Components ........................................................... 15
Disassembly and Assembly ................................... 15
PREPARATION ................................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 16
INSPECTION ...................................................... 18COOLING FAN .......................................................... 19
Components (Crankshaft Driven Type) .................. 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19
Removal and Installation (Motor Driven Type) (Mod-
els with A/C) ........................................................... 19
REMOVAL ........................................................... 19
INSTALLATION ................................................... 20
WATER PUMP .......................................................... 21
Components ........................................................... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
THERMOSTAT AND WATER PIPING ...................... 23
Components ........................................................... 23
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 25
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 26
Standard and Limit .................................................. 26
ENGINE COOLANT CAPACITY .......................... 26
THERMOSTAT .................................................... 26
RESERVOIR TANK ............................................. 26

ENGINE COOLANT
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ENGINE COOLANTPFP:KQ100
InspectionEBS01E6P
LEVEL CHECK
lCheck if the reservoir tank engine coolant level within MIN to
MAX when engine is cool.
lAdjust engine coolant level as necessary.
CHECKING RADIATOR SYSTEM FOR LEAKS
lTo check for leaks of cooling system, apply pressure to the res-
ervoir tank (1) with the radiator cap tester (commercial service
tool) (A) and the radiator cap tester adapter (B) [SST:
EG17650301].
WARNING:
Do not remove reservoir tank cap and/or radiator cap when
engine is hot. Serious burns could occur from high pres-
sure engine coolant escaping from reservoir tank and/or
radiator.
CAUTION:
Higher test pressure than specified may cause cooling system damage.
NOTE:
In a case that engine coolant decreases, replenish radiator and reservoir tank with engine coolant.
lIf anything is found, repair or replace damaged parts.
Changing Engine CoolantEBS01E6Q
WARNING:
lTo avoid being scalded, do not change engine coolant when engine is hot.
lWrap a thick cloth around cap and carefully remove cap. First, turn cap a quarter of a turn to
release built-up pressure. Then turn cap all the way.
lBe careful not to allow engine coolant to contact drive belts.
SMA412B
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2,23psi)
PBIC3501E

ENGINE COOLANT
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3. Fill radiator and reservoir tank to the specified level.
lPour engine coolant through engine coolant filler neck
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.
lUse Genuine Nissan Anti-freeze Coolant (L250) or equiva-
lent in its quality. Refer toMA-14, "
RECOMMENDED FLU-
IDS AND LUBRICANTS".
lWhen engine coolant overflows air relief hole, install air relief
plug.
4. Warm up engine to normal operating temperature without radiator cap and reservoir tank cap installed.
lIf engine coolant overflows radiator filler hole and reservoir tank filler hole, install radiator cap
and reservoir tank cap.
5. Run engine at 3,000 rpm for 10 seconds and return to idle speed with radiator cap installed.
lRepeat two or three times.
CAUTION:
Watch engine coolant temperature gauge so as not to overheat the engine.
6. Stop engine and cool down to less than approximately 50°C(122°F).
lCool down using a fan to reduce the time.
lIf necessary, refill radiator up to filler neck with engine coolant.
7. Refill reservoir tank to MAX level line with engine coolant.
8. Repeat steps 3 through 6 two or more times with radiator cap installed until engine coolant level no longer
drops.
9. Check cooling system for leaks with engine running.
10. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000
rpm with heater temperature controller set at several position between COOL and WARM.
lSound may be noticeable at heater unit.
11. Repeat step 10 three times.
12. If sound is heard, bleed air from cooling system by repeating steps 3 through 6 until engine coolant level
no longer drops.
FLUSHING COOLING SYSTEM
1. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and
reservoir tank with water and reinstall radiator cap and reservoir tank cap.
2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down.
5. Drain water from the system. Refer toCO-8, "
DRAINING ENGINE COOLANT". Engine coolant capacity
(with reservoir tank at “MAX” level)
LHD models
: Approx. 9.9 (8-3/4 lmp qt)
RHD models
: Approx. 10.2 (9 lmp qt)
SMA182B
Reservoir tank capacity (at “MAX” level)
: 0.8 (3/4 lmp qt)
SMA412B

CO-24
THERMOSTAT AND WATER PIPING
Removal and Installation
EBS01E6X
WARNING:
Do not remove radiator cap and/or reservoir tank cap when engine is hot. Serious burns could occur
from high pressure engine coolant escaping from radiator and/or reservoir tank.
REMOVAL
1. Remove front engine undercover and middle engine undercover. Refer toEI-15, "FRONT BUMPER".
2. Drain engine coolant from radiator drain plug at the bottom of radiator, and from water drain plug at the
side of cylinder block. Refer toCO-7, "
Changing Engine Coolant"andEM-110, "CYLINDER BLOCK".
CAUTION:
Perform this step when engine is cold.
3. Remove engine cover. Refer toEM-20, "
INTAKE MANIFOLD".
4. Disconnect radiator hoses (upper and lower) from engine side. Refer toCO-11, "
RADIATOR".
5. Remove air inlet pipe and air duct between air cleaner case and turbocharger. Refer toEM-15, "
AIR
CLEANER AND AIR DUCT"andEM-28, "TURBO CHARGER".
6. Remove water outlet, water inlet and thermostat.
7. Remove thermostat housing.
8. Disconnect heater return hose and water hoses at heater return pipe side, and remove heater return pipe.
9. Remove oil level gauge guide mounting bolt, vacuum hoses (to turbocharger boost control solenoid valve)
and spill hose. Refer toEM-36, "
OIL PAN AND OIL STRAINER",EM-20, "INTAKE MANIFOLD"andEM-
44, "INJECTION TUBE AND FUEL INJECTOR".
10. Disconnect water hoses (to EGR cooler) (A/T models), vacuum hoses and heater feed hose at heater
feed pipe side, and remove heater feed pipe. Refer toEM-20, "
INTAKE MANIFOLD".
INSPECTION AFTER REMOVAL
Thermostat
lPlace a string so that it is caught in the valves of the thermostat.
Immerse fully in a container filled with water. Heat while stirring.
lThe valve opening temperature is the temperature at which the
valve opens and falls from the thread.
lContinue heating. Check the full-open lift amount.
lAfter checking the full-open lift amount, lower the water temper-
ature and check the valve closing temperature.
Standard values
lIf out of the standard, replace thermostat.
INSTALLATION
Note the following, and install in the reverse order of removal.
lSecurely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.
lWhen inserting heater feed pipe end into cylinder head, apply a neutral detergent to O-ring. Then insert it
immediately.
SLC252B
Item Thermostat
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Full-open lift amount More than 9 mm/ 95°C (0.35 in/ 203°F)
Valve closing temperature More than 77°C(171°F)

CO-26
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Standard and LimitEBS01E6Y
ENGINE COOLANT CAPACITY
Unit: (lmp qt)
THERMOSTAT
RESERVOIR TANK
Unit:kPa(bar,kg/cm2, psi)
Engine coolant capacity
(With reservoir tank at “MAX” level)LHD models Approx. 9.9 (8-3/4)
RHD models Approx. 10.2 (9)
Reservoir tank (at “MAX” level)0.8 (3/4)
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Full open lift amount More than 9 mm/ 95°C (0.35 in/203°F)
Valve closing temperature More than 77°C(171°F)
Cap relief pressureStandard 98.2 - 117.8 (0.98 - 1.18, 1.0 - 1.2, 14 - 17)
Limit 59 (0.59, 0.6, 9)
Leakage test pressure 157 (1.57, 1.6, 23)

DI-1
DRIVER INFORMATION SYSTEM
K ELECTRICAL
CONTENTS
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SECTIONDI
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DRIVER INFORMATION SYSTEM
PRECAUTION ............................................................ 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Wiring Diagrams and Trouble Diagnosis .................. 3
COMBINATION METERS ........................................... 4
System Description .................................................. 4
UNIFIED METER CONTROL UNIT ...................... 4
POWER SUPPLY AND GROUND CIRCUIT ........ 4
SPEEDOMETER ................................................... 4
TACHOMETER ..................................................... 4
WATER TEMPERATURE GAUGE ........................ 4
FUEL GAUGE ....................................................... 5
ODO/TRIP METER ............................................... 5
TRIP COMPUTER ................................................ 5
ENGINE OIL MAINTENANCE INFORMATION..... 6
METER ILLUMINATION CONTROL ..................... 6
CLOCK .................................................................. 6
AMBIENT AIR TEMPERATURE INDICATION ...... 6
Component Parts and Harness Connector Location..... 7
Arrangement of Combination Meter ......................... 8
Internal Circuit .......................................................... 9
Wiring Diagram — METER — ................................ 10
Terminals and Reference Value for Combination
Meter ...................................................................... 12
Self-Diagnosis Mode of Combination Meter ........... 13
FUNCTION .......................................................... 13
OPERATION PROCEDURE ............................... 13
TEST ITEM ......................................................... 13
CONSULT-II Function (METER) ............................. 15
CONSULT-II BASIC OPERATION ....................... 15
SELF-DIAG RESULTS ........................................ 16
DATA MONITOR ................................................. 17
Trouble Diagnosis .................................................. 18
HOW TO PERFORM TROUBLE DIAGNOSIS ... 18
PRELIMINARY CHECK ...................................... 19
Symptom Chart ...................................................... 19
Power Supply and Ground Circuit Inspection ........ 19
Vehicle Speed Signal Inspection ............................ 20
Engine Speed Signal Inspection ............................ 21Engine Coolant Temperature Signal Inspection ..... 21
Fuel Level Sensor Signal Inspection ...................... 22
Ambient Sensor Signal Inspection .......................... 24
Fuel Gauge Fluctuates, Indicates Wrong Value, or
Varies ...................................................................... 25
Fuel Gauge Does Not Move to Full position ........... 25
DTC [U1000] CAN Communication Circuit ............. 26
DTC [B2205] Vehicle Speed Circuit ........................ 26
Electrical Components Inspection .......................... 27
FUEL LEVEL SENSOR UNIT CHECK ................ 27
AMBIENT SENSOR CHECK ............................... 27
Removal and Installation of Combination Meter ..... 27
WARNING LAMPS .................................................... 28
System Description ................................................. 28
OIL PRESSURE WARNING LAMP ..................... 28
Component Parts and Harness Connector Location... 28
Schematic ............................................................... 29
Wiring Diagram — WARN — .................................. 30
A/T MODELS ....................................................... 30
M/T MODELS ...................................................... 37
Oil Pressure Warning Lamp Stays Off (Ignition
Switch ON) ............................................................. 44
Oil Pressure Warning Lamp Does Not Turn Off (Oil
Pressure Is Normal) ................................................ 45
Oil Pressure Warning Lamp Keeps Blinking (Oil
Level Is Normal) ..................................................... 46
Component Inspection ............................................ 47
OIL PRESSURE SWITCH ................................... 47
OIL LEVEL SENSOR .......................................... 47
A/T INDICATOR ........................................................ 48
System Description ................................................. 48
Wiring Diagram — AT/IND — ................................. 49
A/T Indicator Does Not Illuminate ........................... 50
WARNING CHIME ..................................................... 51
System Description ................................................. 51
POWER SUPPLY AND GROUND CIRCUIT ....... 51
LIGHT WARNING CHIME ................................... 51
KEY REMINDER WARNING CHIME .................. 51
LOW-FUEL WARNING CHIME ........................... 51
SEAT BELT WARNING CHIME ........................... 52

DI-14
COMBINATION METERS
17 XXXXXDisplays vehicle speed signal value
(MPH).Displays “-----” if message is not received.
Displays “99999” if data received is invalid.
If “-----” or “99999” is displayed, performDI-20, "Ve h i-
cle Speed Signal Inspection".
18 XXXXXDisplays vehicle speed signal value
(km/h).Displays “-----” if message is not received.
Displays “99999” if data received is invalid.
If “-----” or “99999” is displayed, performDI-20, "
Ve h i-
cle Speed Signal Inspection".
19 tXXXXDisplays engine speed signal value
(RPM).Displays “-----” if message is not received.
If “-----” is displayed, performDI-21, "
Engine Speed
Signal Inspection".
20 F1 XXXXDisplays ratioed fuel level sensor signal
value.000-009 = Short circuit
010-254 = Normal range
255 = Open circuit
--- = Missing 5 seconds
If “000-009” or “255” is displayed, performDI-22, "
Fuel
Level Sensor Signal Inspection".
21 XXXCDisplays engine coolant temperature sig-
nal value (°C).Displays “---” C if message is not received.
Displays “999” C if data received is invalid.
If “---” or “999” is displayed, performDI-21, "
Engine
Coolant Temperature Signal Inspection".
22 BAt XXX Displays battery voltage.
23 rES -X Driver's seat belt buckle switch status.1= Buckled
0 = Unbuckled
24 PA -XX — Not used for service.
25 Pb -XX — Not used for service.
26 PE -XX — Not used for service.
27 PL -XX — Not used for service.
28 P6 -XX — Not used for service.
29 Pn -XX — Not used for service.
30 PP -XX — Not used for service.
31 PS -XX — Not used for service.
32 Pt -XX — Not used for service.
33 Pu -XX — Not used for service.
34 P4 -XX — Not used for service.
35 Puu -XX — Not used for service.
36 A00XXX — Not used for service.
37 A01XXX — Not used for service.
38 A02XXX — Not used for service.
39 A03XXX — Not used for service.
40 A04XXX — Not used for service.
41 A05XXX — Not used for service.
42 A06XXX — Not used for service.
43 A07XXX — Not used for service.
44 A08XXX — Not used for service.
45 A09XXX — Not used for service.
46 A10XXX — Not used for service.
47 A11XXX — Not used for service.
48 A12XXX — Not used for service. Te s t
orderTest Item Description of test/data Notes

COMBINATION METERS
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PRELIMINARY CHECK
1.CHECK WARNING LAMPS ILLUMINATION
1. Turn ignition switch ON.
2. Make sure warning lamps (such as malfunction indicator lamp and oil pressure warning indicator) illumi-
nate.
Do warning lamps illuminate?
YES >> GO TO 2.
NO >> Check ignition power supply system of combination meter. Refer toDI-19, "
Power Supply and
Ground Circuit Inspection".
2.CHECK COMBINATION METER (SELF-DIAGNOSIS MODE)
Perform self-diagnosis mode of combination meter function. Refer toDI-13, "
Self-Diagnosis Mode of Combi-
nation Meter".
Does self-diagnosis mode operate normally?
YES >> GO TO 3.
NO >> Check applicable parts, and repair or replace corresponding parts.
3.CHECK COMBINATION METER (CONSULT-II)
Perform self-diagnosis of combination meter. Refer toDI-15, "
CONSULT-II Function (METER)".
Self-diagnosis results
No malfunction detected>>INSPECTION END
Malfunction detected>>Check applicable parts, and repair or replace corresponding parts.
Symptom ChartEKS00L8P
Power Supply and Ground Circuit InspectionEKS00L8O
1.CHECK FUSE
Check for blown fuse of combination meter.
OK or NG
OK >> GO TO 2.
NG >> Be sure to eliminate cause of malfunction before installing new fuse. Refer toPG-4, "
POWER
SUPPLY ROUTING CIRCUIT".
Symptom Possible cause
Speedometer and odo/trip meter indication is malfunction. Refer toDI-20, "
Vehicle Speed Signal Inspection".
Tachometer indication is malfunction. Refer toDI-21, "
Engine Speed Signal Inspection".
Water temperature gauge indication is malfunction. Refer toDI-21, "
Engine Coolant Temperature Signal Inspection".
Fuel gauge indication is malfunction.
Refer toDI-22, "
Fuel Level Sensor Signal Inspection".
Low-fuel warning lamp indication is irregular.
A/T indication is malfunction. Refer toDI-50, "
A/T Indicator Does Not Illuminate".
Ambient air temperature indication is malfunction. Refer toDI-24, "
Ambient Sensor Signal Inspection".
Power source Fuse No.
Battery 19
Ignition switch ON or START 14

DTC P0217 ENGINE OVER TEMPERATURE
EC-133
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CONSULT-II Reference Value in Data Monitor ModeEBS01KFL
Specification data are reference values.
On Board Diagnosis LogicEBS01KFM
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant. Refer toCO-7, "
Changing Engine
Coolant". Also, replace the engine oil. Refer toLU-6, "Changing Engine Oil".
1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer toMA-16, "
Engine Coolant Mixture Ratio".
2. After refilling coolant, run engine to ensure that no water-flow noise is emitted.
Overall Function CheckEBS01KFN
Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be con-
firmed.
WARNING:
lNever remove a radiator cap and/or a reservoir tank cap when the engine is hot. Serious burns
could be caused by high pressure fluid escaping from the radiator and the reservoir tank.
lWrap a thick cloth around 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.
MONITOR ITEM CONDITION SPECIFICATION
COOLING FAN
lEngine: After warming up, idle
the engine
lAir conditioner switch: OFFEngine coolant temperature: 97°C
(207°F) or lessOFF
Engine coolant temperature: Between
98°C (208°F) and 104°C(219°F)LOW
Engine coolant temperature: 105°C
(221°F) or moreHI
DTC No. Trouble diagnosis name DTC detecting condition Possible cause
P0217
0217Engine over temperature
(Overheat)
lCooling fan does not operate properly (Over-
heat).
lCooling fan system does not operate properly
(Overheat).
lEngine coolant was not added to the system
using the proper filling method.
lEngine coolant is not within the specified
range.
lHarness or connectors
(The cooling fan circuit is open or
shorted.)
lIPDM E/R
lCooling fan
lCooling fan (Crankshaft driven)
lRadiator hose
lRadiator
lRadiator cap
lReservoir tank
lReservoir tank cap
lWater pump
lThermostat
For more information, refer toEC-140,
"Main 12 Causes of Overheating".

EC-134
DTC P0217 ENGINE OVER TEMPERATURE
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 toEC-137,
"Diagnostic Procedure".
2. Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go toEC-137,
"Diagnostic Procedure".
3. Turn ignition switch ON.
4. Perform “COOLING FAN” in “ACTIVE TEST” mode with CON-
SULT-II.
5. If the results are NG, go toEC-137, "
Diagnostic Procedure".
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 toEC-137,
"Diagnostic Procedure".
2. Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go toEC-137,
"Diagnostic Procedure".
3. Perform IPDM E/R auto active test and check cooling fan motors operation, refer toPG-19, "
Auto Active
Te s t".
4. If NG, go toEC-137, "
Diagnostic Procedure".
SEF621W
SEF111X
SEF621W