leak INFINITI FX35 2005 Workshop Manual
[x] Cancel search | Manufacturer: INFINITI, Model Year: 2005, Model line: FX35, Model: INFINITI FX35 2005Pages: 4731, PDF Size: 60.13 MB
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BRAKE PIPING AND HOSE BR-11
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BRAKE PIPING AND HOSEPFP:46210
Hydraulic CircuitAFS001MY
CAUTION:
All hoses and piping (tubes) must be free from excessive bending, twisting and pulling.
Make sure there is no interference with other parts when turning steering both clockwise and
counterclockwise.
The brake piping is an important safety part. If a brake fluid leak is detected, always disassemble
the parts. Replace applicable part with a new one, if necessary.
Be careful not to splash brake fluid on painted areas; it way cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
Do not bend or twist brake hose sharply, or strongly pull it.
When removing components, cover connections so that no dirt, dust, or other foreign matter gets
in.
Refill with new brake fluid “ DOT 3 ”.
Do not reuse drained brake fluid.
Removal and Installation of Front Brake Piping and Brake Hose AFS001MZ
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove union bolt and remove brake hose from caliper assembly.
4. Remove lock plate and remove brake hose from the vehicle.
INSTALLATION
1. Install brake hose by aligning with the protrusion on caliper assembly, and tighten union bolt to the specified torque.
NOTE:
Do not reuse copper washer.
2. Install brake hose to brake tube, partially tighten flare nut as far as possible by hand, then secure it to bracket with lock plate.
3. Using a flare nut wrench, tighten flare nut to the specified torque.
4. Refill brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake
System" .
SFIA1941E
SFIA1204E
Page 1121 of 4731
BR-12
BRAKE PIPING AND HOSE
Revision: 2005 July 2005 FX
Removal and Installation of Rear Brake Piping and Brake Hose AFS001N0
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Using a flare nut wrench, remove brake tube from brake hose.
3. Remove bolt.
4. Remove union bolt, and then remove brake hose from caliper assembly.
INSTALLATION
1. Install brake hose to caliper assembly positioning hole and tighten union bolt to the specified torque.
NOTE:
Do not reuse copper washer.
2. Install brake hose to brake tube, partially tighten flare nut as far as possible by hand, then tighten bolt to the specified torque.
3. Using a flare nut wrench, tighten flare nut to the specified torque.
4. Refill brake fluid and bleed air. Refer to BR-10, "
Bleeding Brake
System" .
Inspection After InstallationAFS001N1
CAUTION:
If a leak is detected at the connections, retighten it or, if necessary, replace the damaged part.
1. Check brake lines (tubes and hoses), and connections for fluid leaks, damage, twist, deformation, contact with other parts, and loose connections. Replace any damage parts.
2. While depressing brake pedal under a force of 785 N (80 kg, 177 lb) with engine running for approximately 5 seconds, check for fluid leakage from each part. : 23.5 N·m (2.4 kg-m, 17 ft-lb)
SFIA1942E
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BRAKE MASTER CYLINDER BR-13
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BRAKE MASTER CYLINDERPFP:46010
On-Board InspectionAFS001N2
LEAK INSPECTION
Check for leaking in master cylinder attachment portion, reservoir tank, and brake tube connections.
Removal and InstallationAFS001N3
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
REMOVAL
1. Drain brake fluid. Refer to BR-9, "Drain and Refill" .
2. Disconnect harness connectors for fluid level sensor and pressure sensor.
3. Using a flare nut wrench, disconnect brake tube from master cylinder assembly.
4. Remove master cylinder assembly fixing nut, remove master cylinder assembly from the vehicle. Refer to BR-16, "
Removal and Installation" .
INSTALLATION
Install in the reverse order of removal.
–Refill brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" .
CAUTION:
Refill with new brake fluid “DOT3”.
Do not reuse drained brake fluid.
ComponentsAFS001N4
SFIA2157E
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BR-32
SERVICE DATA AND SPECIFICATIONS (SDS)
Revision: 2005 July 2005 FX
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsAFS001NF
Unit: mm (in)
Brake PedalAFS001NG
Brake BoosterAFS001NH
Vacuum type
Check ValveAFS001NI
Front Disc BrakeAFS001NJ
Rear Disc BrakeAFS001NK
Front brake Rotor outer diameter
× thickness 320 × 28 (12.60 × 1.10)
Pad length × width × thickness 111.0 × 73.5 × 9.5 (4.73 × 2.894 × 0.374)
Cylinder bore diameter 63.6 (2.504)
Rear brake Rotor outer diameter
× thickness 308 × 16 (12.13 × 0.63)
Pad length × width × thickness 83.0 × 33.0 × 8.5 (3.268 × 1.299 × 0.335)
Cylinder bore diameter 42.86 (1.6874)
Master cylinder Cylinder bore diameter 25.4 (1.00)
Control valve Valve model Electric brake force distribution
Brake booster Diaphragm diameter Primary 228.5 (9.0)
Secondary 203.0 (8.0)
Recommended brake fluid DOT 3
Brake pedal height (from dash panel top surface) 161.5 − 171.5 mm (6.36 − 6.75 in)
Depressed pedal height [under a force of 490 N (50 kg, 110 lb)
with engine running] More than 80 mm (3.15 in)
Clearance between stopper rubber and the threaded end of stop
lamp switch 0.74
− 1.96 mm (0.0291 − 0.0772 in)
Pedal play 3 − 11 mm (0.12 − 0.43 in)
Input rod installation standard dimension 126.5 mm (4.98 in)
Vacuum leakage
[at a vacuum of –66.7 kPa (–500 mmHg, –19.69 inHg)] Within a vacuum of 1.3 kPa (10 mmHg, 0.39 inHg) for 15 seconds
Brake pad Standard thickness (new) 9.5 mm (0.374 in)
Repair limit thickness 2.0 mm (0.079 in)
Disc rotor Standard thickness (new) 28.0 mm (1.102 in)
Repair limit thickness 26.0 mm (1.024 in)
Maximum uneven wear (measured at 8 positions) 0.015mm (0.0006 in)
Runout limit (with the disc rotor attached to the vehicle) 0.04 mm (0.0016 in)
Brake pad Standard thickness (new) 8.5 mm (0.335 in)
Repair limit thickness 2.0 mm (0.079 in)
Disc rotor Standard thickness (new) 16.0 mm (0.630 in)
Repair limit thickness 14.0 mm (0.551 in)
Maximum uneven wear (measured at 8 positions) 0.015 mm (0.0006 in)
Runout limit (with the disc rotor attached to the vehi-
cle) 0.05 mm (0.0020 in)
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BRC-1
BRAKE CONTROL SYSTEM
F BRAKES
CONTENTS
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SECTION BRC
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BRAKE CONTROL SYSTEM
VDC/TCS/ABS
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” ............................................................. ..... 3
Precautions for Brake System ............................. ..... 3
Precautions for Brake Control ............................. ..... 3
PREPARATION ...................................................... ..... 5
Special Service Tools .......................................... ..... 5
Commercial Service Tools ................................... ..... 5
ON-VEHICLE SERVICE ........................................ ..... 6
Adjustment of Steering Angle Sensor Neutral Posi-
tion ...................................................................... ..... 6
Calibration of Decel G Sensor (AWD Model) ...... ..... 6
SYSTEM DESCRIPTION ....................................... ..... 8
System Diagram .................................................. ..... 8
VDC Function ...................................................... ..... 8
TCS Function ...................................................... ..... 8
ABS Function ...................................................... ..... 8
EBD Function ...................................................... ..... 9
Fail-Safe Function ............................................... ..... 9
VDC / TCS SYSTEM ........................................ ..... 9
ABS, EBD SYSTEM ......................................... ..... 9
Hydraulic Circuit Diagram ................................... ... 10
CAN COMMUNICATION ....................................... ....11
System Description ............................................. .... 11
TROUBLE DIAGNOSIS ......................................... ... 12
How to Proceed with Diagnosis .......................... ... 12
BASIC CONCEPT ............................................ ... 12
DIAGNOSIS FLOWCHART ............................. ... 13
ASKING COMPLAINTS ................................... ... 14
EXAMPLE OF DIAGNOSIS SHEET ................ ... 14
Component Installation Location ......................... ... 15
Schematic ........................................................... ... 16
Wiring Diagram — VDC — .................................. ... 17
Control Unit Input/Output Signal Standard .......... ... 23
REFERENCE VALUE FROM CONSULT-II ...... ... 23
CONSULT-II Functions ........................................ ... 25
CONSULT-II MAIN FUNCTION ........................ ... 25
CONSULT-II BASIC OPERATION PROCEDURE ... 26
SELF-DIAGNOSIS ........................................... ... 27
DATA MONITOR .............................................. ... 30
ACTIVE TEST .................................................. ... 33
For Fast and Accurate Diagnosis ........................ ... 35
PRECAUTIONS FOR DIAGNOSIS .................. ... 35
Basic Inspection .................................................. ... 36
BASIC INSPECTION 1: BRAKE FLUID
AMOUNT, LEAKS, AND BRAKE PADS INSPEC-
TION ................................................................. ... 36
BASIC INSPECTION 2: POWER SYSTEM TER-
MINAL LOOSENESS AND BATTERY INSPEC-
TION ................................................................. ... 36
BASIC INSPECTION 3: ABS WARNING LAMP,
VDC OFF INDICATOR LAMP, SLIP INDICATOR
LAMP AND BRAKE WARNING LAMP INSPEC-
TION ................................................................. ... 37
Inspection 1: Wheel Sensor Circuit ..................... ... 37
Inspection 2: Engine System ............................... ... 39
Inspection 3: VDC/TCS/ABS Control Unit Circuit ... 40
Inspection 4: Pressure Sensor Circuit ................. ... 40
Inspection 5: Steering Angle Sensor Circuit ........ ... 42
Inspection 6: Yaw Rate/Side G Sensor (2WD
Model), Yaw Rate/Side/Decel G sensor (AWD Mod-
els) Circuit ............................................................ ... 44
Inspection 7: Solenoid and VDC Change-Over
Valve Circuit ......................................................... ... 46
Inspection 8: Actuator Motor Circuit .................... ... 47
Inspection 9: ABS Actuator and Electric Unit (Con-
trol Unit) Power Supply and Ground Circuit ......... ... 48
Inspection 10: Stop Lamp Switch Circuit ............. ... 50
Inspection 11: Brake Fluid Level Switch Circuit ... ... 51
Inspection 12: When “ST ANG SEN SIGNAL”
Appears on Self-diagnosis Results Display ......... ... 52
Inspection 13: When “DECEL G SEN SET” Appears
on Self-diagnostic Results Display (AWD Model) ... 52
Inspection 14: CAN Communication Circuit ........ ... 53
Component Inspection ......................................... ... 53
VDC OFF SWITCH .......................................... ... 53
Symptom 1: Excessive ABS Function Operation
Page 1144 of 4731
![INFINITI FX35 2005 Workshop Manual PRECAUTIONS BRC-3
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Precautions for Supplemental Restraint System (SRS) “AIR BAG”](/img/42/57020/w960_57020-1143.png "INFINITI FX35 2005 Workshop Manual PRECAUTIONS BRC-3
[VDC/TCS/ABS]
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Precautions for Supplemental Restraint System (SRS) “AIR BAG”")
PRECAUTIONS BRC-3
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[VDC/TCS/ABS]PRECAUTIONSPFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER”
AFS00289
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Brake SystemAFS001S3
Recommended fluid is brake fluid “DOT 3”.
Do not reuse drained brake fluid.
Be careful not to splash brake fluid on painted areas such as body. If brake fluid is splashed, wipe it off
and flush area with water immediately.
Do not use mineral oils such as gasoline or kerosene to clean. They will ruin rubber parts and cause
improper operation.
Using a flare nut crowfoot and torque wrench, securely tighten
brake tube flare nuts.
Brake system is an important safety part. If a brake fluid leak is
detected, always disassemble the affected part. If a malfunction
is detected, replace part with a new one.
Before working, turn ignition switch OFF and disconnect electri-
cal connectors of ABS actuator and electric unit (control unit) or
battery negative terminal.
When installing brake piping, be sure to check torque.
WARNING:
Clean brake pads and shoes with a waste cloth, then wipe with
a dust collector.
Precautions for Brake ControlAFS001S4
During VDC/TCS/ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This
is normal.
Just after starting vehicle after turning ignition switch ON, brake pedal may vibrate or motor operating
noise may be heard from engine room. This is a normal status of operation check.
Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel,
or snow-covered (fresh, deep snow) roads.
When an error is indicated by ABS or another warning lamp, collect all necessary information from cus-
tomer (what symptoms are present under what conditions) and check for simple causes before starting
diagnostic servicing. Besides electrical system inspection, check booster operation, brake fluid level, and
fluid leaks.
If tire size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts,
stopping distance or steering stability may deteriorate.
SBR686C
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![INFINITI FX35 2005 Workshop Manual BRC-36
[VDC/TCS/ABS]
TROUBLE DIAGNOSIS
Revision: 2005 July 2005 FX
ON and OFF Timing for ABS Warning Lamp, VDC OFF Indicator Lamp, SLIP Indicator Lamp,
Brake Warning Lamp
× : ON –: OFF
NOTE:
1.](/img/42/57020/w960_57020-1176.png "INFINITI FX35 2005 Workshop Manual BRC-36
[VDC/TCS/ABS]
TROUBLE DIAGNOSIS
Revision: 2005 July 2005 FX
ON and OFF Timing for ABS Warning Lamp, VDC OFF Indicator Lamp, SLIP Indicator Lamp,
Brake Warning Lamp
× : ON –: OFF
NOTE:
1.")
BRC-36
[VDC/TCS/ABS]
TROUBLE DIAGNOSIS
Revision: 2005 July 2005 FX
ON and OFF Timing for ABS Warning Lamp, VDC OFF Indicator Lamp, SLIP Indicator Lamp,
Brake Warning Lamp
× : ON –: OFF
NOTE:
1. Brake warning lamp will turn on in case of operating parking brake (switch turned on) or of actuating brake fluid level switch (brake fluid is insufficient).
2. After starting engine, turn OFF.
Basic InspectionAFS001SS
BASIC INSPECTION 1: BRAKE FLUID AMOUNT, LEAKS, AND BRAKE PADS INSPECTION
1. Check fluid level in the brake reservoir tank. If fluid level is low, refill brake fluid.
2. Check brake piping and around ABS actuator and electric unit (control unit) for leaks. If there is leaking or oozing fluid, check the following items.
If ABS actuator and electric unit (control unit) connection is loose, tighten piping to the specified torque
and re-perform the leak inspection to make sure there are no leaks.
If there is damage to the connection flare nut or ABS actuator and electric unit (control unit) screw,
replace the damaged part and re-perform the leak inspection to make sure there are no leaks.
When there is fluid leaking or oozing from a part other than ABS actuator and electric unit (control unit)
connection, if fluid is just oozing out, use a clean cloth to wipe off the oozing fluid and re-check for
leaks. If fluid is still oozing out, replace the damaged part.
When there is fluid leaking or oozing at ABS actuator and electric unit (control unit), if fluid is just oozing
out, use a clean cloth to wipe off oozing fluid and re-check for leaks. If fluid is still oozing out, replace
ABS actuator and electric unit (control unit) body.
CAUTION:
ABS actuator and electric unit (control unit) body can not be disassembled.
3. Check brake pad degree of wear. Refer to BR-20, "
PAD WEAR INSPECTION" in “Front Disc Brake” and
BR-26, "
PAD WEAR INSPECTION" in “Rear Disc Brake”
BASIC INSPECTION 2: POWER SYSTEM TERMINAL LOOSENESS AND BATTERY INSPEC-
TION
Make sure battery positive cable, negative cable and ground connection are not loose. If looseness is
detected, tighten the cables. In addition, check the battery voltage to make sure it has not dropped and alter-
nator is normal.
Condition ABS warning
lamp VDC OFF indi-
cator lamp SLIP indicator
lamp Brake warning
lamp [Note 1] Remarks
Ignition switch OFF. – – – — —
Approx. 2 seconds after igni-
tion switch is turned ON. ××××
[Note 2] —
Approx. 2 seconds later after
ignition switch ON. –––
× [Note 2] Go out 2 seconds after
ignition switch is turned
ON.
VDC OFF SW is turned ON.
(VDC/TCS function is OFF.) –
× –— —
VDC/TCS/ABS error. ××× — There is an ABS actua-
tor and electric unit
(control unit) error.
(Power, ground or sys-
tem malfunction)
When VDC/TCS is not func-
tioning normally. –
×× ——
EBD error. ×××× —
Page 1178 of 4731
![INFINITI FX35 2005 Workshop Manual TROUBLE DIAGNOSIS BRC-37
[VDC/TCS/ABS]
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BASIC INSPECTION 3: ABS WARNING LAMP, VDC OFF INDICATOR LAMP, SLIP INDICATOR
LAMP AND BRAK](/img/42/57020/w960_57020-1177.png "INFINITI FX35 2005 Workshop Manual TROUBLE DIAGNOSIS BRC-37
[VDC/TCS/ABS]
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BASIC INSPECTION 3: ABS WARNING LAMP, VDC OFF INDICATOR LAMP, SLIP INDICATOR
LAMP AND BRAK")
TROUBLE DIAGNOSIS BRC-37
[VDC/TCS/ABS]
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BASIC INSPECTION 3: ABS WARNING LAMP, VDC OFF INDICATOR LAMP, SLIP INDICATOR
LAMP AND BRAKE WARNING LAMP INSPECTION
1. Make sure ABS warning lamp, VDC OFF indicator lamp (when VDC OFF switch is OFF), and SLIP indica-
tor lamp turn on approximately 2 second, and brake warning lamp turns on when ignition switch is turned
ON. If they do not, check VDC OFF indicator lamp and then VDC OFF switch. Refer to BRC-53, "
VDC
OFF SWITCH" . Check CAN communications. Refer to “CAN Communication Inspection”. If there are no
errors with VDC OFF switch and CAN communication system, check combination meter. Refer to DI-5,
"COMBINATION METERS" .
2. Make sure ABS warning lamp, VDC OFF indicator lamp, SLIP indicator lamp turn off approximately 2 sec- ond after turn ignition switch ON, and brake warning lamp turns off after engine starts. If lamps do not turn
off, perform self-diagnosis.
3. With engine running, make sure VDC OFF indicator lamp turns on and off when VDC OFF switch is turned ON and OFF. If indicator lamp status does not correspond to switch operation, check the VDC OFF
switch system. Refer to BRC-53, "
VDC OFF SWITCH" .
4. Make sure ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp turn off 2 seconds after engine is started. If ABS warning lamp, VDC OFF indicator lamp, and SLIP indicator lamp have not turned
off 10 seconds after engine has been started, perform self-diagnosis of ABS actuator and electric unit
(control unit).
5. After performing the self-diagnosis, be sure to erase the error memory. Refer to BRC-27, "
SELF-DIAGNO-
SIS" .
CAUTION:
Brake warning lamp turns on when parking brake is operated (switch on) and brake fluid level
switch is activated (leak of brake fluid).
Inspection 1: Wheel Sensor CircuitAFS001ST
DTC C1101-C1108
After using the CONSULT-II SELF-DIAG RESULTS to determine the location of the malfunctioning wheel sen-
sor, check all areas to determine the component to be replaced.
CAUTION:
Do not measure the resistance value and also voltage between sensor terminal with tester etc.,
because sensor is an active sensor.
Do not expand terminal of connector with a tester terminal stick, when it does the inspection with
tester.
INSPECTION PROCEDURE
1. CHECK TIRE
Check air pressure, wear and size.
Are air pressure, wear, and size within the standard values?
YES >> GO TO 2.
NO >> Adjust air pressure, or replace tire.
2. CHECK SENSOR AND SENSOR ROTOR
Check the condition of the sensor mount (for looseness, etc.).
Check the surface of front sensor rotor rubber for damage.
Check rear sensor rotor for damage.
OK or NG
OK >> GO TO 3.
NG >> Repair sensor mount or replace sensor rotor.
Page 1195 of 4731
![INFINITI FX35 2005 Workshop Manual BRC-54
[VDC/TCS/ABS]
TROUBLE DIAGNOSIS
Revision: 2005 July 2005 FX
Symptom 2: Unexpected Pedal ReactionAFS001T8
1. CHECK BRAKE PEDAL STROKE
Check brake pedal stroke.
Is the stroke too long?
YES >>B](/img/42/57020/w960_57020-1194.png "INFINITI FX35 2005 Workshop Manual BRC-54
[VDC/TCS/ABS]
TROUBLE DIAGNOSIS
Revision: 2005 July 2005 FX
Symptom 2: Unexpected Pedal ReactionAFS001T8
1. CHECK BRAKE PEDAL STROKE
Check brake pedal stroke.
Is the stroke too long?
YES >>B")
BRC-54
[VDC/TCS/ABS]
TROUBLE DIAGNOSIS
Revision: 2005 July 2005 FX
Symptom 2: Unexpected Pedal ReactionAFS001T8
1. CHECK BRAKE PEDAL STROKE
Check brake pedal stroke.
Is the stroke too long?
YES >>Bleed air from brake piping.
Check brake pedal, brake booster, and master cylinder mount for play, looseness, and brake
system for fluid leaks, etc. If any malfunctions are found, make repair.
NO >> GO TO 2.
2. CHECK FUNCTION
Disconnect ABS actuator and electric unit (control unit) connector E56 and make sure that braking force is suf-
ficient when ABS in not operating. After the inspection, reconnect connector.
OK or NG
OK >> GO TO symptom 1 “Step 2”. Refer to BRC-53, "Symptom 1: Excessive ABS Function Operation
Frequency" .
NG >> Check brake system.
Symptom 3: The Braking Distance is LongAFS001T9
CAUTION:
On slippery road surfaces, the stopping distance might be longer with the ABS operating than when
the ABS is not operating.
1. CHECK FUNCTION
Disconnect ABS actuator and electric unit (control unit) connector E56 to deactivate ABS. In this condition,
check stopping distance. After inspection, connect connector.
OK or NG
OK >>Bleed air from brake piping.
Check brake system.
NG >> GO TO symptom 1 “Step 2”. Refer to BRC-53, "
Symptom 1: Excessive ABS Function Operation
Frequency" .
Page 1206 of 4731
CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
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SECTION CO
A
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Revision: 2005 July 2005 FX
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 Chart ...................................................... ... 10
ENGINE COOLANT ............................................... ....11
Inspection ............................................................ .... 11
LEVEL CHECK ................................................ .... 11
LEAK CHECK .................................................. .... 11
Changing Engine Coolant ................................... .... 11
DRAINING ENGINE COOLANT ...................... .... 11
REFILLING ENGINE COOLANT ..................... ... 12
FLUSHING COOLING SYSTEM ...................... ... 13
RADIATOR ............................................................. ... 14
Components ........................................................ ... 14
Removal and Installation ..................................... ... 14
REMOVAL ........................................................ ... 14
INSTALLATION ................................................ ... 15
INSPECTION AFTER INSTALLATION ............ ... 15
Checking Radiator Cap ....................................... ... 15
Checking Radiator ............................................... ... 16
RADIATOR (ALUMINUM TYPE) ........................... ... 17
Components ........................................................ ... 17
Disassembly and Assembly ................................ ... 17
PREPARATION ................................................ ... 17
DISASSEMBLY ................................................ ... 17
ASSEMBLY ...................................................... ... 18
INSPECTION ................................................... ... 20 COOLING FAN .......................................................
... 21
Components ........................................................ ... 21
Removal and Installation ..................................... ... 21
REMOVAL ........................................................ ... 21
INSTALLATION ................................................ ... 21
INSPECTION AFTER INSTALLATION ............. ... 21
Disassembly and Assembly ................................. ... 21
DISASSEMBLY ................................................ ... 21
INSPECTION AFTER DISASSEMBLY ............. ... 21
ASSEMBLY ...................................................... ... 21
WATER PUMP ....................................................... ... 22
Components ........................................................ ... 22
Removal and Installation ..................................... ... 22
REMOVAL ........................................................ ... 22
INSPECTION AFTER REMOVAL .................... ... 24
INSTALLATION ................................................ ... 24
INSPECTION AFTER INSTALLATION ............. ... 25
WATER INLET AND THERMOSTAT ASSEMBLY . ... 26
Components ........................................................ ... 26
Removal and Installation ..................................... ... 26
REMOVAL ........................................................ ... 26
INSPECTION AFTER REMOVAL .................... ... 27
INSTALLATION ................................................ ... 27
INSPECTION AFTER INSTALLATION ............. ... 27
WATER OUTLET AND WATER PIPING ................ ... 28
Components ........................................................ ... 28
Removal and Installation ..................................... ... 28
REMOVAL ........................................................ ... 28
INSTALLATION ................................................ ... 29
INSPECTION AFTER INSTALLATION ............. ... 29
SERVICE DATA AND SPECIFICATIONS (SDS) ... ... 30
Standard and Limit ............................................... ... 30
ENGINE COOLANT CAPACITY (APPROXI-
MATE) ............................................................... ... 30
RADIATOR ....................................................... ... 30
THERMOSTAT ................................................. ... 30