coolant reservoir NISSAN PICK-UP 1998 Repair Manual

Overheat
ON BOARD DIAGNOSIS LOGIC
If the cooling fan or another component in the cooling system malfunctions, the engine coolant temperature
will rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
Diagnostic trouble
code No.Malfunction is detected when ...Check Items
(Possible Cause)
28
lEngine coolant temperature reaches an abnormally
high temperature.lCooling fan
lRadiator hose
lRadiator
lRadiator cap
lWater pump
lThermostat
For more information, refer to ``MAIN 12
CAUSES OF OVERHEATING'', EC-108.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in MA sec-
tion (``Changing Engine Coolant'', ``ENGINE MAINTENANCE''). Also, replace the engine oil.
lFill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pour-
ing coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to MA section
(``Anti-freeze Coolant Mixture Ratio'', ``RECOMMENDED FLUIDS AND LUBRICANTS'').
lAfter refilling coolant, run engine to ensure that no water-flow noise is emitted.
OVERALL FUNCTION CHECK
WARNING:
Never remove the radiator cap when the engine is hot. Seri-
ous burns could be caused by high pressure fluid escaping
from the radiator.
Wrap 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.
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 step and go to
``DIAGNOSTIC PROCEDURE'' on next page.
2. Confirm whether customer filled the coolant or not. If cus-
tomer filled the coolant, go to ``DIAGNOSTIC PROCEDURE''
on next page.
AEC640
TROUBLE DIAGNOSIS FOR ``OVER HEAT'' (DTC 28)KA
EC-106

MAIN 12 CAUSES OF OVERHEATING
Engine Step Inspection item Equipment Standard Reference page
OFF 1
lBlocked radiator
lBlocked condenser
lBlocked radiator grille
lBlocked bumper
lVisual No blocking Ð
2
lCoolant mixturelCoolant tester 50 - 50% coolant mixture See ``RECOMMENDED
FLUIDS AND LUBRI-
CANTS'' in MA section.
3
lCoolant levellVisual Coolant up to MAX level
in reservoir tank and
radiator filler neckSee ``Changing Engine
Coolant'', ``ENGINE
MAINTENANCE'' in MA
section.
4
lRadiator caplPressure tester 78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0
kg/cm
2, 11 - 14 psi)
59 - 98 kPa (0.59 - 0.98
bar, 0.6 - 1.0 kg/cm
2,
9 - 14 psi) (Limit)See ``System Check'',
``ENGINE COOLING
SYSTEM'' in LC section.
ON*2 5
lCoolant leakslVisual No leaks See ``System Check'',
``ENGINE COOLING
SYSTEM'' in LC section.
ON*2 6
lThermostatlTouch the upper and
lower radiator hosesBoth hoses should be hot. See ``Thermostat'' and
``Radiator'', ``ENGINE
COOLING SYSTEM'' in
LC section.
ON*1 7
lCooling fanlVisual Operating See ``Cooling Fan'',
``ENGINE COOLING
SYSTEM'' in LC section.
OFF 8
lCombustion gas leaklColor checker chemical
tester 4 gas analyzerNegative Ð
ON*3 9
lCoolant temperature
gaugelVisual Gauge less than 3/4
when drivingÐ
lCoolant overflow to res-
ervoir tanklVisual No overflow during driving
and idlingSee ``Changing Engine
Coolant'', ``ENGINE
MAINTENANCE'' in MA
section.
OFF*4 10
lCoolant return from res-
ervoir tank to radiatorlVisual Should be initial level in
reservoir tankSee ``ENGINE MAINTE-
NANCE'' in MA section.
OFF 11
lCylinder headlStraight gauge feeler
gauge0.1 mm (0.004 in) Maxi-
mum distortion (warping)See ``Inspection'', ``CYL-
INDER HEAD'' in EM
section.
12
lCylinder block and pis-
tonslVisual No scuffing on cylinder
walls or pistonSee ``Inspection'', ``CYL-
INDER BLOCK'' in EM
section.
*1: Engine running at idle.
*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 to ``OVERHEATING CAUSE ANALYSIS'' in LC section.
TROUBLE DIAGNOSIS FOR ``OVER HEAT'' (DTC 28)KA
Overheat (Cont'd)
EC-108

INSTALLATION
1. Use a scraper to remove old liquid gasket from water inlet.
lAlso remove traces of liquid gasket from mating surface
of front cover.
2. Apply a continuous bead of liquid gasket to mating surface
of water inlet.
lUse Genuine Liquid Gasket or equivalent.
3. Install thermostat with jiggle valve or air bleeder at upper
side.
4. Install water inlet housing.
5. Install water hose to water inlet housing.
6. Install air cleaner and air duct assembly.
7. Refill engine coolant. Refer to MA section (``Changing Engine
Coolant'', ``ENGINE MAINTENANCE'').
lAfter installation run engine for a few minutes, and
check for leaks.
Radiator
REMOVAL AND INSTALLATION
1. Drain coolant from radiator. Refer to MA section (``Changing
Engine Coolant'', ``ENGINE MAINTENANCE'').
2. Disconnect upper and lower radiator hoses.
3. Remove air cleaner and air duct assembly.
4. Remove lower radiator shroud.
5. Remove radiator shroud.
6. Disconnect coolant reservoir hose.
7. Remove radiator.
8. After replacing radiator, install all parts in reverse order of
removal.
9. Refill engine coolant. Refer to MA section (``Changing Engine
Coolant'', ``ENGINE MAINTENANCE'').
lAfter installation, run engine for a few minutes, and
check for leaks.
SLC824-A
SLC097
ENGINE COOLING SYSTEMKA
Thermostat (Cont'd)
LC-9

Radiator
REMOVAL AND INSTALLATION
1. Remove under cover.
2. Drain coolant from radiator drain plug.
3. Disconnect radiator upper and lower hoses.
4. Remove radiator lower shroud.
5. Disconnect reservoir tank hose.
6. Remove radiator.
7. After repairing or replacing radiator, install any part removed
in reverse order of removal.
Refilling Engine Coolant
For details on refilling engine coolant, refer to MA section
(``REFILLING ENGINE COOLANT'', ``Changing Engine Cool-
ant'').
DLC008
ENGINE COOLING SYSTEMTD
LC-24

Overheating Cause Analysis
Symptom Check items
Cooling
system parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
Ð Thermostat stuck closed Ð
Damaged finsDust contamination or paper
clogging
Mechanical damage
Clogged radiator cooling tubeExcess foreign material (rust,
dirt, sand, etc.)
Reduced air flowCooling fan does not operate
ÐÐ Fan coupling does not operate
High resistance to fan rotation
Damaged fan blades
Damaged radiator shroud Ð Ð Ð
Improper coolant mixture ratio Ð Ð Ð
Poor coolant quality Ð Ð Ð
Insufficient coolantCoolant leaksCooling hoseLoose clamp
Cracked hose
Water pump Poor sealing
Radiator capLoose
Poor sealing
RadiatorO-ring for damage, deteriora-
tion 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 deteriora-
tion
Except
cooling
system parts
malfunctionÐ Overload on engineAbusive drivingHigh engine rpm under no load
Driving in low gear for extended
time
Driving at extremely high speed
Powertrain system malfunction
Ð Installed improper size wheels
and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air flowBlocked bumper Ð
Ð Blocked radiator grilleInstalled car brassiere
Mud contamination or paper
clogging
Blocked radiator Ð
Blocked condenser
Ð
Installed large fog lamp
ENGINE COOLING SYSTEM
LC-31

Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD Ð engine off
hRadiator coolant level and coolant hose con-
nections for leaks
hBattery fluid level, specific gravity and condi-
tions of battery terminals
hDrive belts tension
hFuel filter for water or dusts, and fuel lines and
connections for leaks
hEngine oil level and oil leaks
hClutch and brake reservoir fluid level and fluid
lines for leaks
hWindshield and rear window washer and head-
lamp cleaner reservoir fluid level
hPower steering reservoir fluid level and hose
connections for leaks
ON INSIDE AND OUTSIDE
hRemove front spring/strut spacer (If applicable)
hOperation of all instruments, gauges, lights and
accessories
hOperation of horn(s), wiper and washer
hSteering lock for operation
hCheck air conditioner for gas leaks
hFront and rear seats, and seat belts for opera-
tion
hAll moldings, trims and fittings for fit and align-
ment
hAll windows for operation and alignment
hHood, trunk lid, door panels for fit and align-
ment
hLatches, keys and locks for operation
hWeatherstrips for adhesion and fit
hHeadlamp aiming
hTighten wheel nuts (Inc. inner nuts if appli-
cable)
hTire pressure (Inc. spare tire)
hCheck front wheels for toe-in
hInstall clock/voltmeter/room lamp fuse (If appli-
cable)
UNDER BODY
hManual transmission/transaxle gear oil, trans-
fer fluid and differential gear oil level
hBrake and fuel lines and oil/fluid reservoirs for
leaks
hTighten bolts and nuts of steering linkage and
gear box, suspension, propeller shafts and
drive shafts
ROAD TEST
hClutch operation
hParking brake operation
hService brake operation
hSteering control and returnability
hEngine performance
hSqueaks and rattles
ENGINE OPERATING AND HOT
hAdjust idle mixture and speed (and ignition tim-
ing*1)
hEngine idling and stop knob operation (Diesel
only)
FINAL INSPECTION
hInstall necessary parts (outside mirror, wheel
covers, seat belts, mat, carpet or mud flaps)
hInspect for interior and exterior metal and paint
damage
hCheck for spare tire, jack, tools (wheel chock),
and literature
hWash, clean interior and exterior
*1: Not required on models with a direct ignition system
h
X: Not applicable to this model.
PRE-DELIVERY INSPECTION ITEMS
MA-3

General maintenance includes those items which should be checked during the normal day-to-day opera-
tion of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can per-
form the checks and inspections themselves or they can have their NISSAN dealers do them.
Item Reference pages
OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless otherwise
specified.
TiresCheck the pressure with a gauge periodically when at a service station, including the
spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or
excessive wear.Ð
Windshield wiper bladesCheck for cracks or wear if they do not wipe properly. Ð
Doors and engine hoodCheck that all doors, the engine hood, the trunk lid and back door
operate properly. Also ensure that all latches lock securely. Lubricate hinges, latches, rollers and
links if necessary. Make sure that the secondary latch keeps the hood from opening when the
primary latch is released.
When driving in areas using road salt or other corrosive materials, check for lubrication fre-
quently.MA-39
Tire rotationTires should be rotated every 10,000 km (6,000 miles) for 2WD models and every
5,000 km (3,000 miles) for 4WD models.MA-35
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when per-
forming periodic maintenance, cleaning the vehicle, etc.
LightsMake sure that the headlights, stop lights, tail lights, turn signal lights, and other lights
are all operating properly and installed securely. Also check headlight aim.Ð
Warning lights and chimesMake sure that all warning lights and chimes are operating prop-
erly.Ð
Steering wheelCheck for change in the steering conditions, such as excessive free play, hard
steering or strange noises.
Free play: Less than 35 mm (1.38 in)Ð
Seat beltsCheck that all parts of the seat belt system (e.g. buckles, anchors, adjusters and
retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for
cuts, fraying, wear or damage.MA-40
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically e.g. each time you check the
engine oil or refuel.
Windshield washer fluidCheck that there is adequate fluid in the tank. Ð
Engine coolant levelCheck the coolant level when the engine is cold. MA-16, 25
Engine oil levelCheck the level after parking the vehicle on a level spot and turning off the
engine.MA-19, 24
Brake and clutch fluid levelMake sure that the brake and clutch fluid levels are between the
``MAX'' and ``MIN'' lines on the reservoir.MA-32, 35
BatteryCheck the fluid level in each cell. It should be between the ``MAX'' and ``MIN'' lines. Ð
GENERAL MAINTENANCE
MA-4

Fluids and Lubricants
Capacity (Approximate)
Recommended Fluids/Lubricants
Liter Imp qt
Engine oil (Refill)
With oil filterKA24E2WD 3.9
4WD 4.13-3/8 qt
3-5/8 qt
Gasoline engine: API SG or SH*1
Diesel engine: API CD*1 TD25 7.2 6-3/8 qt
Without oil filterKA24E2WD 3.5
4WD 3.73-1/8 qt
3-1/4 qt
TD25 6.5 5-3/4 qt
Cooling system (With reservoir)
KA24E 6.7 5-7/8 qt
Anti-freeze coolant (Ethylene glycol base) or
soft water
TD25 9.5 8-3/8 qt
Manual transmission gear oil
FS5R30A 4WD 5.1 9 pt
API GL-4*1
FS5W71C2WD 2.0
4WD 4.93-1/2 pt
8-5/8 pt
Transfer fluid TX10A 2.2 2 qtNissan Matic ``D'' or Equivalent Automatic
Transmission Fluid*2 or API GL-4*1
Differential gear oil
Front: R180A 1.3 2-1/4Standard differential gear: API GL-5*1
Limited-slip differential (LSD) gear: Gear Oil
Hypoid LSD
(Part No.: KLD31-14002) or equivalent*3 Rear: H233B 2.8 2 - 1/2
C200 1.3 1 - 1/8
Power steering fluid ± þType DEXRON
TMIIE, DEXTRONTMIII or
equivalent
Brake and clutch fluid ± ±For Europe: DOT 3 or DOT 4 (US FMVSS
No. 116)*5 Except for Europe: DOT 3 (US
FMVSS No. 116)
Propeller shaft grease ± ±NLGI No. 2 (Molybdenum disulphide lithium
soap base)
Multi-purpose grease ± ± NLGI No. 2 ( Lithium soap base)
*1: For further details, see ``SAE Viscosity Number''.
*2: Contact a NISSAN dealership for more information regarding suitable fluid, including recommended brand(s) of DEXRONTMIII/
MERCONTMAutomatic Transmission Fluid.
*3: API GL-5, SAE 140 and 10% volume of LSD Friction Modifier (Part No.: 38469-C6000) is an equivalent.
*4: Never mix DOT 3 and DOT 4. (DOT 3 is filled at factory.)
RECOMMENDED FLUIDS AND LUBRICANTS
MA-12

Changing Engine Coolant
WARNING:
To avoid being scalded, never change the coolant when the
engine is hot.
Ð DRAINING ENGINE COOLANT Ð
1. Move heater ``TEMP'' control lever all the way to ``HOT''
position.
lMake sure that air condition switch is ``OFF''.
2. Open radiator drain plug at the bottom of radiator, and
remove radiator cap.
3. Remove reservoir tank, drain coolant, then clean reservoir
tank. Install it temporarily.
Be careful not to allow coolant to contact drive belts.
4. Remove cylinder block drain plug.
Ð FLUSHING COOLING SYSTEM Ð
5. Install and then tighten radiator drain plug and cylinder block
drain plug securely.
6. Open air relief plug.
7. Fill radiator with water and close air relief plug and radiator
cap.
8. Run engine and warm it up sufficiently.
9. Race engine 2 or 3 times under no-load.
10. Stop engine and wait until it cools down.
11. Repeat step 2 through step 10 until clear water begins to
drain from radiator.
12. Drain water.
Ð REFILLING ENGINE COOLANT Ð
lApply sealant to the thread of drain plug.
: 34-44Nzm
(3.5 - 4.5 kg-m, 25 - 33 ft-lb)
SMA917C
SMA918CA
SMA919C
SMA580C
ENGINE MAINTENANCEKA
MA-16

13. Open radiator cap and air relief plug.
14. Fill radiator with coolant up to specified level.
Follow instructions attached to anti-freeze container for mix-
ing ratio of anti-freeze to water.
For coolant mixture ratio, refer to MA-14.
Unit:!(Imp qt)
Coolant capacity:
2WD 4WD
Without reservoir tank 6.1 (5-3/8)
Reservoir tank 0.6 (1/2)
Pour coolant through coolant filler neck slowly to allow air
in system to escape.
15. Close air relief plug.
16. Remove reservoir tank, drain coolant, then clean reservoir
tank.
17. Install reservoir tank and fill it with coolant up to ``MAX'' level
and then install radiator cap.
18. Run engine and warm it up sufficiently.
19. Race engine 2 or 3 times under no-load.
20. Stop engine and cool it down, then add coolant as neces-
sary.
Checking Cooling System
CHECKING HOSES
Check hoses for proper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATOR CAP
Apply pressure to radiator cap by means of a cap tester to see
if it is satisfactory.
Radiator cap relief pressure:
Standard
78-98kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm
2, 11 - 14 psi)
Limit
59-98kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm
2,9-14psi)
Pull the negative-pressure valve to open it. Check that it closes
completely when released.
SMA182B
SMA920C
SLC769A
SMA871B
ENGINE MAINTENANCEKA
Changing Engine Coolant (Cont'd)
MA-17