overheating NISSAN NAVARA 2005 Repair Workshop Manual

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
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SECTIONCO
A
CO
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

CO-4
OVERHEATING CAUSE ANALYSIS
OVERHEATING CAUSE ANALYSIS
PFP:00012
Troubleshooting ChartEBS01E6M
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-
ateRefer toEC-132, "
DTC
P0217 ENGINE OVER
TEMPERATURE"
—
Highresistancetofanrota-
tion
Fan assembly
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

OVERHEATING CAUSE ANALYSIS
CO-5
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MA
CO
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
Blocked air flow
Installed large fog lamp Symptom Check items

EC-2
DTC Confirmation Procedure ................................. 88
Diagnostic Procedure ............................................. 89
Component Inspection ............................................ 90
Removal and Installation ........................................ 91
DTC P0102, P0103 MAF SENSOR ........................... 92
Component Description .......................................... 92
CONSULT-II Reference Value in Data Monitor Mode
... 92
ECM Terminals and Reference Value ..................... 92
On Board Diagnosis Logic ...................................... 93
DTC Confirmation Procedure ................................. 93
Wiring Diagram ....................................................... 94
Diagnostic Procedure ............................................. 95
Component Inspection ............................................ 96
Removal and Installation ........................................ 97
DTC P0112, P0113 IAT SENSOR ............................. 98
Component Description .......................................... 98
On Board Diagnosis Logic ...................................... 98
DTC Confirmation Procedure ................................. 98
Wiring Diagram .....................................................100
Diagnostic Procedure ...........................................101
Component Inspection ..........................................102
Removal and Installation ......................................102
DTC P0117, P0118 ECT SENSOR ..........................103
Description ............................................................103
On Board Diagnosis Logic ....................................103
DTC Confirmation Procedure ...............................103
Wiring Diagram .....................................................105
Diagnostic Procedure ...........................................106
Component Inspection ..........................................107
Removal and Installation ......................................107
DTC P0122, P0123 APP SENSOR .........................108
Description ............................................................108
CONSULT-II Reference Value in Data Monitor Mode
.108
ECM Terminals and Reference Value ...................108
On Board Diagnosis Logic ....................................109
DTC Confirmation Procedure ...............................109
Wiring Diagram .....................................................110
Diagnostic Procedure ............................................111
Component Inspection ..........................................112
Removal and Installation ......................................112
DTC P0182, P0183 FUEL PUMP TEMPERATURE
SENSOR ..................................................................113
Description ............................................................113
CONSULT-II Reference Value in Data Monitor Mode
.113
ECM Terminals and Reference Value ...................113
On Board Diagnosis Logic ....................................113
DTC Confirmation Procedure ...............................114
Wiring Diagram .....................................................115
Diagnostic Procedure ...........................................116
Removal and Installation ......................................117
DTC P0192, P0193 FRP SENSOR .........................118
Description ............................................................118
CONSULT-II Reference Value in Data Monitor Mode
.118
ECM Terminals and Reference Value ...................118
On Board Diagnosis Logic ....................................118DTC Confirmation Procedure ................................119
Wiring Diagram .....................................................120
Diagnostic Procedure ............................................121
Component Inspection ..........................................122
Removal and Installation .......................................122
DTC P0200 FUEL INJECTOR .................................123
On Board Diagnosis Logic ....................................123
DTC Confirmation Procedure ................................123
Diagnostic Procedure ............................................123
DTC P0201 - P0204 FUEL INJECTOR ...................125
Component Description ........................................125
CONSULT-II Reference Value in Data Monitor Mode
.125
ECM Terminals and Reference Value ...................125
On Board Diagnosis Logic ....................................126
DTC Confirmation Procedure ................................127
Wiring Diagram .....................................................128
Diagnostic Procedure ............................................129
Component Inspection ..........................................130
Removal and Installation .......................................131
DTC P0217 ENGINE OVER TEMPERATURE ........132
Description ............................................................132
CONSULT-II Reference Value in Data Monitor Mode
.133
On Board Diagnosis Logic ....................................133
Overall Function Check .........................................133
Wiring Diagram .....................................................135
Diagnostic Procedure ............................................137
Main 12 Causes of Overheating ...........................140
Component Inspection ..........................................141
DTC P0222, P0223 APP SENSOR .........................142
Description ............................................................142
CONSULT-II Reference Value in Data Monitor Mode
.142
ECM Terminals and Reference Value ...................142
On Board Diagnosis Logic ....................................143
DTC Confirmation Procedure ................................143
Wiring Diagram .....................................................144
Diagnostic Procedure ............................................145
Component Inspection ..........................................146
Removal and Installation .......................................146
DTC P0234 TC SYSTEM .........................................147
Description ............................................................147
ECM Terminals and Reference Value ...................147
On Board Diagnosis Logic ....................................148
Overall Function Check .........................................148
Wiring Diagram .....................................................149
Diagnostic Procedure ............................................150
Component Inspection ..........................................152
Removal and Installation .......................................152
DTC P0237, P0238 TC BOOST SENSOR ..............153
Component Description ........................................153
CONSULT-II Reference Value in Data Monitor Mode
.153
ECM Terminals and Reference Value ...................153
On Board Diagnosis Logic ....................................154
DTC Confirmation Procedure ................................154
Wiring Diagram .....................................................155
Diagnostic Procedure ............................................156

DTC P0217 ENGINE OVER TEMPERATURE
EC-133
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EC
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-138
DTC P0217 ENGINE OVER TEMPERATURE
5.CHECK RESERVOIR TANK CAP
Apply pressure to cap with a tester and check reservoir tank cap
relief pressure.
Refer toCO-13, "
Checking Reservoir Tank Cap".
OK or NG
OK >> GO TO 6.
NG >> Replace reservoir tank cap.
6.CHECK COMPONENT PARTS
Check the following.
lThermostat. Refer toCO-23, "THERMOSTAT AND WATER PIPING".
lEngine coolant temperature sensor. Refer toEC-107, "Component Inspection".
OK or NG
OK >> GO TO 7.
NG >> Replace malfunctioning component.
7.CHECK MAIN 12 CAUSES
If the cause cannot be isolated, go toEC-140, "
Main 12 Causes of Overheating".
>>INSPECTION END
SLC755AC

EC-140
DTC P0217 ENGINE OVER TEMPERATURE
5.CHECK COOLING FAN MOTOR
Refer toEC-141, "
Component Inspection".
OK or NG
OK >> GO TO 6.
NG >> Replace cooling fan motors.
6.CHECK INTERMITTENT INCIDENT
PerformEC-70, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT".
OK or NG
OK >> Replace IPDM E/R. Refer toPG-14, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MOD-
ULE ENGINE ROOM)".
NG >> Repair or replace harness or connector.
Main 12 Causes of OverheatingEBS01KFQ
*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer toCO-4, "
OVERHEATING CAUSE ANALYSIS". Engine Step Inspection item Equipment Standard Reference page
OFF 1
lBlocked radiator
lBlocked condenser
lBlocked radiator grille
lBlocked bumper
lVisual No blocking —
2
lCoolant mixturelCoolant tester 50 - 50% coolant mixture SeeMA-16, "Engine
Coolant Mixture Ratio".
3
lCoolant levellVisual Coolant up to MAX level
in reservoir tank and radi-
ator filler neckSeeCO-7, "LEVEL
CHECK".
4
lReservoir tank caplPressure tester SeeCO-13, "Checking Reservoir Tank Cap".
ON*
25lCoolant leakslVisual No leaks SeeCO-7, "CHECKING
RADIATOR SYSTEM
FOR LEAKS".
ON*
26lThermostatlTouch the upper and
lower radiator hosesBoth hoses should be hot SeeCO-23, "THERMO-
STAT AND WATER PIP-
ING".
ON*
17lCooling fanlCONSULT-II Operating See trouble diagnosis for
DTC P0217 (EC-132
).
ON*
27lCooling fan (Crankshaft
driven)lVisual OperatingSeeCO-19, "COOLING
FA N".
OFF 8
lCombustion gas leaklColor checker chemical
tester 4 Gas analyzerNegative —
ON*
39lCoolant temperature
gaugelVisual Gauge less than 3/4
when driving—
lCoolant overflow to
reservoir tanklVisual No overflow during driving
and idlingSeeCO-7, "Changing
Engine Coolant".
OFF*
410lCoolant return from
reservoir tank to radia-
torlVisual Should be initial level in
reservoir tankSeeCO-7, "LEVEL
CHECK".
OFF 11
lCylinder headlStraight gauge feeler
gauge0.1 mm (0.004 in) Maxi-
mum distortion (warping)SeeEM-92, "CYLINDER
HEAD".
12
lCylinder block and pis-
tonslVisual No scuffing on cylinder
walls or pistonSeeEM-110, "CYLIN-
DER BLOCK".

AXLE SHAFT
RAX-11
[M226]
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RAX
INSPECTION AFTER DISASSEMBLY
Axle Shaft
lClean and remove all nicks and burrs.
lCheck for straightness and distortion. Replace if necessary.
lInspect machined surfaces for evidence of overheating, damage and wear. Replace if necessary.
lMeasure the bearing ring retainer axle journal diameter. Replace if necessary.
ASSEMBLY
1. Install a new grease catcher onto the axle shaft.
2. Reinstall studs on the axle shaft retainer, and install the axle shaft retainer on the axle shaft.
3. Install a new seal lip onto the axle shaft.
CAUTION:
lSeal lip can not be reused. Do not attempt to reuse it.
lWhen installing oil seals, apply multi-purpose grease to oil seal lips.
4. Install a new bearing on the axle shaft.
CAUTION:
lWheel bearing can not be reused. Do not attempt to reuse it.
5. Using a bearing inserter, and a suitable press, press fit the axle
shaft to the new bearing ring retainer, until the snap ring groove.
CAUTION:
lMake sure the bearing ring retainer, axle shaft bearing,
axle shaft lip seal, and axle shaft retainer are installed
facing in the correct direction.
lBearing ring retainer can not be reused. Do not attempt to
reuse it.
6. Apply grease to the bearing cup, and install onto the axle shaft
bearing.
7. Install a new snap ring using a suitable snap ring pliers.
CAUTION:
Discard the old snap ring: replace with new ones.
8. Install the new ABS rotor sensor. Refer toBRC-39, "
SENSOR ROTOR".
CAUTION:
Discard the old sensor rotor; replace with a new one.Bearing ring retainer axle journal diameter (minimum)
: 45.027 mm (1.7727 in)
MDIB9047E