cooling fan NISSAN ALMERA N16 2003 Electronic Repair Manual

ENGINE ASSEMBLY
EM-69
[QG]
C
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EM
●Center member
●Front exhaust tube
●Stabilizer bar
●Cooling fan
●Radiator
●Disconnect wires, harness, pipes, hoses and so on.
10. Lift up engine slightly and disconnect or remove all engine
mountings.
When lifting engine, be sure to clear surrounding parts. Use
special care near brake tubes and brake master cylinder.
11. Remove engine with transaxle as shown.
INSTALLATION
●Install in reverse order of removal.
SEM108G
SEM420D

Removal and InstallationNJEM0101
JEM264G
PREPARATIVE WORKNJEM0101S01Remove the following parts.
Under cover
Engine coolant (drain)
Refer to LC-43, “Changing Engine Coolant”.
Radiator upper hose
Cooling fan
Refer to LC-42, “Radiator”.
Radiator mount bracket
Water inlet pipe
Exhaust front tube (disconnect)
Refer to FE-26, “Removal and Installation”, “EXHAUST SYS-
TEM”.
CATALYSTNJEM0101S02RemovalNJEM0101S0201Remove the catalyst, refer to above illustration.
CAUTION:
Do not disassemble.
InstallationNJEM0101S0202Install two locking pins into both sides of the catalytic converter. Be
careful not to confuse locking pins with insulator mounting bolts.
Catalytic converter locking pin:
Flange bolt (black)
Insulator mounting bolt:
Washer bolt (silver or yellow)
CATALYSTYD
Removal and Installation
EM-36

crankshaft position sensor (TDC sensor) from the assem-
bly.
Always pay extra attention not to damage edge of crank-
shaft position sensor (TDC sensor) or ring gear teeth.
REMOVALNJEM0069S011. Remove engine undercover, and hood for hoisting.
2. Drain coolant from both cylinder block and radiator. Refer to
LC-43, “Changing Engine Coolant”.
3. Remove the following parts:
Battery
RH and LH front wheels
RH and LH splash covers (combined with undercover)
Auxiliary belts
Alternator
Alternator brackets
Radiator and cooling fan
Engine cover
Air ducts and air cleaner case
LH side of engine room:
4. Disconnect all harnesses and grounds that are connected to
components on vehicle.
5. Disconnect vacuum hose on vacuum pump side.
6. Disconnect fuel feed and fuel return hoses on engine side.
Immediately put blind plugs into the openings to prevent
fuel from flowing out.
7. Disconnect heater hose. Plug opening of hose to prevent cool-
ant from flowing out.
RH side of engine room:
8. Remove air conditioner compressor from brackets and move
it toward vehicle side. Secure compressor on vehicle side with
rope.
Vehicle underside:
9. Remove exhaust front tube.
10. Disconnect two hoses from power steering pump and plug to
stop fluid.
11. Remove M/T control rod and support rod.
12. Remove ABS wheel sensor, and temporarily hang brake cali-
per with rope on vehicle side.
13. Remove RH and LH drive shafts.
YEM024
14. Install engine slingers to cylinder head.
: 30 - 37 N·m (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
Use engine slingers and securing bolts of the specified
service parts.
15. Lift up vehicle to appropriate level where work can be per-
formed efficiently. Using two transmission jacks, securely sup-
port engine oil pan and bottom surface of transaxle.
ENGINE ASSEMBLYYD
Removal and Installation (Cont’d)
EM-64

ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION
LC
CONTENTS
QG
ENGINE LUBRICATION SYSTEM..................................3
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..............3
LIQUID GASKET APPLICATION PROCEDURE............3
Preparation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[..............3
SPECIAL SERVICE TOOLS........................................3
Lubrication Circuit ........................................................4
Oil Pressure Check......................................................5
Oil Pump <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[..............5
REMOVAL AND INSTALLATION.................................5
DISASSEMBLY AND ASSEMBLY................................6
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>7
REGULATOR VALVE INSPECTION............................7
Changing Engine Oil....................................................8
Changing Oil Filter .......................................................9
Service Data and Specifications (SDS).....................10
OIL PRESSURE CHECK..........................................10
OIL PUMP INSPECTION..........................................10
REGULATOR VALVE INSPECTION..........................10
OIL CAPACITY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>0
ENGINE COOLING SYSTEM........................................ 11
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............ 11
LIQUID GASKET APPLICATION PROCEDURE.......... 11
Preparation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............ 11
SPECIAL SERVICE TOOLS...................................... 11
Cooling Circuit ...........................................................12
System Check<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[........12
CHECKING COOLING SYSTEM HOSES...................12
CHECKING RADIATOR............................................13
CHECKING RADIATOR CAP....................................13
CHECKING COOLING SYSTEM FOR LEAKS............13
Water Pump <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[.........14
REMOVAL AND INSTALLATION...............................14
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>4
Thermostat <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............15
REMOVAL AND INSTALLATION...............................15
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>6
Radiator <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[..............16
COMPONENTS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>6
Cooling Fan <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........17
COMPONENTS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>7
CONTROL SYSTEM................................................17
Changing Engine Coolant..........................................17
- DRAINING ENGINE COOLANT -............................17
- REFILLING ENGINE COOLANT -...........................18
- FLUSHING COOLING SYSTEM -............................19
Radiator (Aluminum type) ..........................................20
PREPARATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>0
DISASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>0
ASSEMBLY<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011001100110011001100110011>1
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>2
Overheating Cause Analysis .....................................23
Service Data and Specifications (SDS).....................24
THERMOSTAT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>4
RADIATOR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011001100110011>24
COOLANT CAPACITY..............................................24
YD
ENGINE LUBRICATION SYSTEM................................25
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............25
LIQUID GASKET APPLICATION PROCEDURE..........25
Preparation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............25
SPECIAL SERVICE TOOLS......................................25
Lubrication Circuit ......................................................26
Oil Pressure Check....................................................27
Oil Pump <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011[............27
REMOVAL AND INSTALLATION...............................27
DISASSEMBLY AND ASSEMBLY..............................28
OIL PUMP INSPECTION..........................................28
REGULATOR VALVE INSPECTION..........................29
Changing Engine Oil..................................................30
Oil Filter Bracket ........................................................31
REMOVAL AND INSTALLATION...............................31
Changing Oil Filter .....................................................31
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[32
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>2
Oil Cooler <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[.............33
REMOVAL AND INSTALLATION...............................33
Service Data and Specifications (SDS).....................34
OIL PRESSURE CHECK..........................................34
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REGULATOR VALVE INSPECTION..........................34
OIL PUMP INSPECTION..........................................34
ENGINE OIL CAPACITY...........................................34
ENGINE COOLING SYSTEM........................................35
Precautions <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............35
LIQUID GASKET APPLICATION PROCEDURE..........35
Preparation <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[............35
SPECIAL SERVICE TOOLS......................................35
Cooling Circuit ...........................................................36
System Check<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[........37
CHECKING COOLING SYSTEM HOSES...................37
CHECKING RADIATOR............................................37
CHECKING RADIATOR CAP....................................37
CHECKING COOLING SYSTEM FOR LEAKS............38
Water Pump <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[.........38
REMOVAL AND INSTALLATION...............................38
REMOVAL<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[39
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>9
INSTALLATION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>9
Thermostat <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[............40
REMOVAL AND INSTALLATION...............................40
INSPECTION<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011>1
Radiator <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011[..............41
COMPONENTS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>1
REMOVAL AND INSTALLATION...............................42
Cooling Fan <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[..........42
COMPONENTS<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011001100110011>2
CONTROL SYSTEM................................................42
Changing Engine Coolant..........................................43
- DRAINING ENGINE COOLANT -............................43
- REFILLING ENGINE COOLANT -...........................43
- FLUSHING COOLING SYSTEM -............................45
Radiator (Aluminum type) ..........................................46
Overheating Cause Analysis .....................................46
Service Data and Specifications (SDS).....................47
THERMOSTAT<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011>7
RADIATOR<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011001100110011>47
ENGINE COOLANT CAPACITY................................47
CONTENTS(Cont’d)
LC-2

CHECKING RADIATORNJLC0017S04Check radiator for mud or clogging. If necessary, clean radiator as
follows.
Be careful not to bend or damage the radiator fins.
When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, rediator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1. Apply water by hose to the back side of the radiator core ver-
tically download.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor.
4. Blow air into the back side of radiator core vertically download.
Use compressesd air lower than 490 kPa (4.9 bar, 5 kg/cm
2,
71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.
SLC613-A
CHECKING RADIATOR CAPNJLC0017S03To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm
2, 11 - 14 psi)
Limit
59 - 98 kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm
2,9-14psi)
SMA967B
Pull the negative pressure valve to open it.
Check that it closes completely when released.
SLC756AA
CHECKING COOLING SYSTEM FOR LEAKSNJLC0017S02To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2,23psi)
CAUTION:
Higher pressure than specified may cause radiator damage.
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ENGINE COOLING SYSTEMQG
System Check (Cont’d)
LC-13

SLC343
INSPECTIONNJLC00221. Check for valve seating condition at normal room temperature.
It should seat tightly.
2. Check valve opening temperature and valve lift.
Valve opening temperature °C (°F) 82 (180)
Valve lift mm/°C (in/°F) More than 8/95 (0.31/203)
3. Then check if valve closes at 5°C (9°F) below valve opening
temperature.
Radiator
COMPONENTSNJLC0025
YLC016
1. Reservoir tank
2. Reservoir tank bracket
3. Reservoir hose
4. Radiator cap5. Mounting bracket
6. Radiator
7. Mounting rubber
8. Lower radiator hose9. Oil cooler hose (A/T models)
10. Upper radiator hose
11. Cooling fan assembly
ENGINE COOLING SYSTEMQG
Thermostat (Cont’d)
LC-16

Cooling FanNJLC0026COMPONENTSNJLC0026S01
YLC023
CONTROL SYSTEMNJLC0026S02Cooling fans are controlled by the ECM. For details, refer to
EC-324 or EC-596, “DTC P1217 ENGINE OVER
TEMPERATURE”.
Changing Engine CoolantNJLC0037WARNING:
To avoid the danger of being scalded, never change the cool-
ant when the engine is hot.
— DRAINING ENGINE COOLANT —NJLC0037S011. Set air conditioning system as follows to prevent coolant from
remaining in the system.
a. Turn ignition switch ON and set temperature controller to maxi-
mum hot position.
b. Wait 10 seconds before turning ignition switch OFF.
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ENGINE COOLING SYSTEMQG
Cooling Fan
LC-17

SMA182B
SMA412B
Refer to MA-19, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Coolant capacity (With reservoir tank):
Unit:(Imp qt)
M/T 6.7 (5-7/8)
A/TFor Sedan 6.6 (5-7/8)
For Hatchback 6.7 (5-7/8)
Reservoir tank capacity:
0.7(5/8 Imp qt)
Pour coolant through coolant filler neck slowly to allow air
in system to escape.
3. Fill radiator and reservoir tank to specified level.
4. Warm up engine to normal operating temperature without
radiator cap installed.
If coolant overflows radiator filler hole, install filler cap.
5. Run engine at 2,500 rpm for 10 seconds and return to idle
speed with radiator cap installed.
Repeat two or three times.
Watch coolant temperature gauge so as not to overheat the
engine.
6. Stop engine and cool it down.
Cool down using a fan to reduce the time.
If necessary, refill radiator up to filler neck with coolant.
7. Refill reservoir tank to MAX level line with coolant.
8. Repeat steps 4 through 7 two or more times with radiator cap
installed until coolant level no longer drops.
9. Check cooling system for leaks with engine running.
10. Warm up engine, and check for sound of coolant flow while
running engine from idle up to 3,000 rpm with heater tempera-
ture controller set at several positions between COOL and
HOT.
Sound may be noticeable at heater water cock.
11. If sound is heard, bleed air from cooling system by repeating
steps 4 through 7 until coolant level no longer drops
Clean excess coolant from engine.
— FLUSHING COOLING SYSTEM —NJLC0037S031. Open air relief plug.
2. 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.
3. Run engine and warm it up to normal operating temperature.
4. Rev engine two or three times under no-load.
5. Stop engine and wait until it cools down.
6. Drain water.
7. Repeat steps 1 through 6 until clear water begins to drain from
radiator.
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ENGINE COOLING SYSTEMQG
Changing Engine Coolant (Cont’d)
LC-19

SLC934
2. Check for leakage.
Overheating Cause AnalysisNJLC0028
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
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ENGINE COOLING SYSTEMQG
Radiator (Aluminum type) (Cont’d)
LC-23