NISSAN X-TRAIL 2003 Electronic Repair Manual

THERMOSTAT AND WATER CONTROL VALVE
CO-21
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THERMOSTAT AND WATER CONTROL VALVEPFP:21200
Removal and InstallationEBS009SK
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
Thermostat Removal
1. Drain engine coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
CAUTION:
Perform when the engine cold.
2. Disconnect radiator lower hose at water inlet side.
3. Remove water inlet and thermostat.
Water Control Valve Removal
1. Drain engine coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
2. Disconnect upper radiator hose, heater pipe and heater hose at water outlet side.
3. Remove water outlet.
4. Remove water control valve.
PBIC0239E
1 Thermostat 2 Water inlet 3 Water control valve
4 Water outlet 5 Heater hose 6 Engine coolant temperature sensor
7Heaterpipe

CO-22
[QR20DE]
THERMOSTAT AND WATER CONTROL VALVE
INSPECTION AFTER REMOVAL
lPlace a string 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 the
thermostat.)
lThe valve opening temperature is the temperature at which the
valve opens and the falls from the thread.
lContinue heating. Check the full-open lift amount.
NOTE:
The full-open lift amount standard temperature for the water
control valve is the reference value.
lAfter checking the full-open lift amount, lower the water temper-
ature and check the valve closing temperature.
Standard values
INSTALLATION
lInstall in the reverse order of removal paying attention to the following.
Installation of Thermostat and Water Control Valve
lInstall the thermostat and water control valve with the whole cir-
cumference of each flange part fit securely inside the rubber
ring. (The example in the figure shows the thermostat.)
lInstall the thermostat with the jiggle valve facing upwards. (The
position deviation may be within the range of±10°)
lInstall the water control valve with the up-mark facing up and the
frame center part facing upwards. (The position deviation may
be within the range of±10°)
Heater Pipe Installation
lFirst apply a neutral detergent to the O-ring, then quickly insert the insertion parts of the heater pipe into
the installation holes.
SLC252B
Thermostat Water control valve
Valve opening temperature 80.5 - 83.5°C(177-182°F) 93.5 - 96.5°C (200 - 206°F)
Full-open lift amountMore than 8 mm/ 95°C
(0.315 in/ 203°F)More than 8 mm/ 108°C
(0.315 in/ 226°F)
Valve closing temperature 77°C(171°F) 90°C (194°F)
PBIC0157E
PBIC0158E

SERVICE DATA AND SPECIFICATIONS (SDS)
CO-23
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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-24
[YD22DDTi]
PRECAUTIONS
[YD22DDTi]PRECAUTIONSPFP:00001
Precautions For Liquid GasketEBS00BAU
REMOVAL AND LIQUID GASKET
lAfter removing the mounting bolts and nuts, disconnect and
remove the liquid gasket using a seal cutter.
CAUTION:
Be careful not to damage the mating surfaces.
lIn areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the gasket applied area.
CAUTION:
If for some unavoidable reason a tool such as a flat-blade
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
lRemove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the gasket without breaks to the specified location with the
specified dimensions.
lIf there is a groove for the liquid gasket application, apply the
gasket to the groove.
lAs for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the service manual.
lWithin five minutes of gasket application, install the mating com-
ponent.
lIf the liquid gasket protrudes, wipe it off immediately.
lDo not retighten after the installation.
lAfter 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are specific instructions in the service manual, observe
them.
PBIC0275E
PBIC0003E
EMA0622D
SEM164F

PREPARATION
CO-25
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PREPARATIONPFP:00002
Special Service ToolsEBS00BAV
Tool number
Tool nameDescription
WS39930000
Tube pressurePressing the tube of liquid gasket
EG17650301
Radiator cap tester adapterAdapting 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 AInstalling radiator upper and lower tanks
KV99103520
Radiator plate pliers BRemoving radiator upper and lower tanks
S-NT052
S-NT564
S-NT224
S-NT225

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

OVERHEATING CAUSE ANALYSIS
CO-27
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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 mal-
function
— 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 Symptom Check items

CO-28
[YD22DDTi]
COOLING SYSTEM
COOLING SYSTEM
PFP:21020
Cooling CircuitEBS00BAX
SBIA0127E

COOLING SYSTEM
CO-29
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SBIA0128E

CO-30
[YD22DDTi]
ENGINE COOLANT
ENGINE COOLANT
PFP:KQ100
InspectionEBS00BAY
LEVEL CHECK
lCheck if the reservoir tank coolant level within MIN to MAX when
engine is cool.
lAdjust coolant if too much or too little.
LEAK CHECK
lTo check for leakage, apply pressure to the cooling system with
atester.
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.
CAUTION:
Higher pressure than specified may cause radiator damage.
Changing Engine CoolantEBS00BAZ
WAR NIN G:
lTo avoid being scalded, never change the coolant when the engine is hot.
lWrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn
to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT
1. Open radiator drain plug at the bottom of radiator, and remove
radiator cap.
lBe careful not to allow coolant to contact drive belts.
lCover the exhaust tube heat shield to prevent from splashing
coolant.
2. Remove reservoir tank, drain coolant, then clean reservoir tank.
SMA412B
Testing pressure
: 157 kPa (1.57bar 1.6 kg/cm2,23psi)
SLC134B
PBIC0236E