radiator NISSAN VERSA 2006 Workshop Service Workshop Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 2006, Model line: VERSA, Model: NISSAN VERSA 2006Pages: 2896, PDF Size: 64.73 MB
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FRONT GRILLE
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FRONT GRILLEPFP:62310
Removal and InstallationEIS0096N
REMOVAL
1. Open hood assembly.
2. Remove the clips, then remove upper radiator cover.
3. Remove the upper clips and release the lower pawls, then pull outward to remove the front grille.
INSTALLATION
Installation is in the reverse order of removal.
LIIA2564E
1. Upper radiator cover 2. Front grille 3. Front bumper fascia
4. Clip C205 Pawl
Page 1847 of 2896
EM-38Revision: June 2006
TIMING CHAIN
2007 Versa
Removal and InstallationEBS00U7N
CAUTION:
The rotating direction indicated in the text indicates all directions seen from the engine front.
REMOVAL
1. Remove front RH wheel. Refer to WT-6, "ROAD WHEEL TIRE ASSEMBLY" .
2. Remove front fender protector (RH). Refer to EI-22, "
FENDER PROTECTOR" .
3. Drain engine oil. Refer to LU-5, "
ENGINE OIL" .
NOTE:
Perform this step when engine is cold.
4. Remove the following parts.
Rocker cover: Refer to EM-30, "Components" .
Drive belt: Refer to EM-13, "Components" .
Water pump pulley: Refer to CO-17, "Components" .
Ground cable (between engine bracket (RH) and radiator core support)
5. Support the bottom surface of engine using a transmission jack, and then remove the engine bracket and
insulator (RH). Refer to EM-73, "
ENGINE ASSEMBLY" .
6. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front
cover.
b. At the same time, make sure that the cam noses of the No.1 cyl-
inder are located ( ) as shown.
If not, rotate crankshaft pulley one revolution (360 degrees)
and align as shown.
13.Timing chain tension guide (front
cover side)14. Crankshaft sprocket 15. Oil pump sprocket
16. Oil pump drive chain 17. Camshaft sprocket (INT) 18. Timing chain tension guide
19. O-ring 20. Chain tensioner (for oil pump)
A. Refer to EM-42
B. Refer to EM-51
C : White paint mark (Not use for service)
PBIC3960E
1 : Camshaft (INT)
2 : Camshaft (EXH)
: Engine front
PBIC3359J
Page 1883 of 2896
EM-74Revision: June 2006
ENGINE ASSEMBLY
2007 Versa
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with a transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.
For supporting points for lifting and jacking point at rear axle, refer to GI-42, "Garage Jack and
Safety Stand and 2-Pole Lift" .
REMOVAL
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
1. Remove engine undercover
2. Drain engine coolant from radiator. Refer to CO-8, "
Changing Engine Coolant" .
CAUTION:
Perform this step when the engine is cold.
Do not spill engine coolant on drive belt.
3. Remove front fender protector (RH and LH); Refer to EI-22, "
FENDER PROTECTOR" .
4. Remove exhaust front tube; Refer to EX-3, "
EXHAUST SYSTEM" .
5. Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-8, "
FRONT DRIVE SHAFT" .
6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to AT - 2 5 3 , "
TRAN-
SAXLE ASSEMBLY" (A/T models), CVT-207, "TRANSAXLE ASSEMBLY" (CVT) or MT-15, "TRAN-
SAXLE ASSEMBLY" (M/T models).
7. Remove rear torque rod (1).
NOTE:
A/T model shown CVT and M/T models similar.
8. Remove hood assembly. Refer to BL-14, "
HOOD" .
9. Remove cowl top cover and cowl top extension assembly. Refer to EI-20, "
COWL TOP" .
10. Release fuel pressure. Refer to EC-81, "
FUEL PRESSURE RELEASE" .
11. Remove battery and battery tray; Refer to SC-4, "
BATTERY" .
12. Remove drive belt; Refer to EM-13, "
Components" .
13. Remove air duct and air cleaner case assembly; Refer to EM-16, "
AIR CLEANER AND AIR DUCT" .
14. Remove cooling fan assembly.
15. Remove radiator hose (upper and lower). Refer to CO-11, "
RADIATOR" .
16. Disconnect A/T, CVT fluid cooler hoses. Refer to CO-11, "
RADIATOR"
17. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then tem-
porarily secure the engine harness into the engine side.
CAUTION:
Protect connectors using a resin bag to protect against foreign materials during the operation.
18. Disconnect fuel feed hose at engine side. Refer to EM-33, "
Components" .
19. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-20,
"Components" .
20. Disconnect control cable from transaxle. Refer to CVT-191, "
SHIFT CONTROL SYSTEM" (CVT) or AT -
229, "SHIFT CONTROL SYSTEM" (A/T), MT-12, "CONTROL LINKAGE" (MT).
21. Remove ground cable at transaxle side.
22. Remove ground cable between front cover and vehicle.
23. Remove alternator. Refer to SC-24, "
CHARGING SYSTEM" .
LBIA0460E
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PRECAUTIONS
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To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
Dispose of or recycle drained oil or the solvent used for cleaning
parts in an appropriate manner.
Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel
spray and possibly a fire.
Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new
ones.
Replace inner and outer races of tapered roller bearings and needle bearings as a set.
Arrange the disassembled parts in accordance with their assembled locations and sequence.
Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
Use only the fluids and lubricants specified in this manual.
Use approved bonding agent, sealants or their equivalents when required.
Use hand tools, power tools (disassembly only) and recom-
mended special tools where specified for safe and efficient ser-
vice repairs.
When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks.
Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
WA RN ING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precautions for Three Way CatalystEAS001ZB
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
When checking for ignition spark or measuring engine compression, make tests quickly and only when
necessary.
SGI233
PBIC0190E
SGI234
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GW-8
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Revision: June 20062007 Versa
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid bumpers out of adjustment
2. Trunk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun visor shaft shaking in the holder
3. Front or rear windshield touching headliner and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
OVERHEAD CONSOLE (FRONT AND REAR)
Overhead console noises are often caused by the console panel clips not being engaged correctly. Most of
these incidents are repaired by pushing up on the console at the clip locations until the clips engage.
In addition look for:
1. Loose harness or harness connectors.
2. Front console map/reading lamp lense loose.
3. Loose screws at console attachment points.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. The rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.
Page 2099 of 2896
IDX-6
ALPHABETICAL INDEX
R
Radiator ............................................................ CO-11
Rear axle .......................................................... RAX-4
Rear combination lamp removal and installation LT-87
Rear door .......................................................... GW-47
Rear seat belt ...................................................... SB-6
Rear suspension ............................................... RSU-5
Rear washer .................................................... WW-30
Rear window defogger ...................................... GW-50
Rear wiper ....................................................... WW-30
Refrigerant connection precaution .................... MTC-5
Refrigerant discharging evacuating charging . MTC-80
Refrigerant general precaution ......................... MTC-5
Refrigerant lines .............................................. MTC-80
Refrigerant pressure sensor ............. EC-586, MTC-88
Refrigeration cycle .......................................... MTC-16
Remote keyless entry system ............................ BL-54
Removal and installation (A/T) ......................... AT-253
Reverse idler shaft (M/T) ................................... MT-18
Reverse lamp switch (M/T) - See Back-up lamp switch
(M/T) .................................................................. MT-11
Reverse main gear (M/T) ................................... MT-18
Road test ......... AT-58, AT-61, AT-64, AT-65, CVT-46
Room lamp - See Interior lamp ........................... LT-91
RP/SEN - Wiring diagram ................................ EC-587
S
SAE J1979 - Service $01 - 09 ........................... EC-47
Seat belt inspection ................................ SB-8, MA-27
Seat belt, front ..................................................... SB-3
Seat belt, rear ...................................................... SB-6
Secondary pressure sensor ........................... CVT-129
Secondary Speed Sensor ................................ CVT-95
SECPS - Wiring diagram ............................... CVT-130
SECPSV - Wiring diagram ............................. CVT-125
Self-diagnostic results .......................... EC-64, EC-116
SEN/PW - Wiring diagram ............................... EC-431
SESCVT - Wiring diagram ............................... CVT-96
SHIFT - Wiring diagram ................... AT-236, CVT-198
Shift control ...................................................... CVT-26
Shift control components (M/T) .......................... MT-21
Shift control system ....................................... CVT-191
Shift fork (M/T) ................................................... MT-21
Shift lever ........................................................... MT-12
Shift lock system .............................................. AT-235
Shift schedule ..................... AT-67, CVT-53, CVT-210
Shock absorber (rear) ....................................... RSU-9
Side air bag (satellite) sensor ......................... SRS-50
Side curtain air bag ......................................... SRS-47
Side trim .............................................................. EI-32
SMJ (super multiple junction) ............................ PG-75
Specification value ........................................... EC-133
Speedometer ........................................................ DI-5
Spiral cable ..................................................... SRS-44
Spot lamp .......................................................... LT-107
SPSW - Wiring diagram ................................. CVT-171
SROOF - Wiring diagram ................................... RF-13
SRS - See Supplemental Restraint System ...... SRS-4
SRS - Wiring diagram ..................................... SRS-13
SRS Trouble diagnoses .................................... SRS-9
SSV/A - Wiring diagram ................................... AT-152
SSV/B - Wiring diagram ................................... AT-157
Stall Test ......................................................... CVT-43
Stall test (A/T) .................................................... AT-53
START - Wiring diagram ................................... SC-12
Starting system ................................................. SC-10
Steering linkage ................................................. PS-12
Steering wheel and column ........................ PS-6, PS-9
Steering wheel turning force ................................ PS-6
Step motor .................................... CVT-164, CVT-168
STM - Wiring diagram ................................... CVT-165
Stop lamp ................................................ LT-71, LT-87
Stop lamp switch ............................................. EC-488
STOP/L - Wiring diagram ................................... LT-71
STSIG - Wiring diagram .................................. CVT-73
Sun roof, electric ................................................ RF-10
Sunroof .................................................. RF-10, RF-22
Supplemental Restraint System ........................ SRS-4
Suspension ....................................................... MA-26
Swirl control valve ........................................... EC-592
Symbols and abbreviations ...................... GI-10, GI-23
Symptom matrix chart ....................................... EC-92
Synchronizer (M/T) ........................................... MT-18
System readiness test (SRT) code ................... EC-52
T
Tachometer ........................................................... DI-5
Tail lamp ............................................................ LT-87
TAIL/L - Wiring diagram ..................................... LT-78
TCM circuit diagram ........................................ CVT-42
TCM function ................................................... CVT-24
TCM inspection table ........................... AT-78, CVT-54
TCV - Wiring diagram ...................... AT-135, CVT-106
Telephone .......................................................... AV-49
Theft warning system - See Vehicle security (Theft warn-
ing) system ....................................................... BL-193
Thermo control amp ........................................ MTC-63
Thermostat ........................................................ CO-18
Three way catalyst function ............................ EC-334
Three way catalyst precautions ............................ GI-5
Throttle control motor relay ............................. EC-493
Throttle position sensor (TPS) .. EC-206, EC-302, EC-
460, EC-462, EC-526
Throttle valve closed position learning .............. EC-78
Tie-rod ................................................................ PS-12
Timing chain ...................................................... EM-37
TLID - Wiring diagram ...................................... BL-177
Torque converter installation .... AT-254, AT-369, CVT-
208
Torque convertor clutch solenoid valve CVT-105, CVT-
110
TPS1 - Wiring diagram .................................... EC-304
TPS2 - Wiring diagram .................................... EC-208
TPS3 - Wiring diagram .................................... EC-528
Transmission case (M/T) .................................. MT-17
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SQUEAK AND RATTLE TROUBLE DIAGNOSES
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Tapping or moving the components or pressing on them while driving to duplicate the conditions can isolate
many of these incidents. You can usually insulate the areas with felt cloth tape or insulator foam blocks from
the NISSAN Squeak and Rattle Kit (J-43980) to repair the noise.
TRUNK
Trunk noises are often caused by a loose jack or loose items put into the trunk by the owner.
In addition look for:
1. Trunk lid bumpers out of adjustment
2. Trunk lid striker out of adjustment
3. The trunk lid torsion bars knocking together
4. A loose license plate or bracket
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area can often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun visor shaft shaking in the holder
3. Front or rear windshield touching headliner and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
OVERHEAD CONSOLE (FRONT AND REAR)
Overhead console noises are often caused by the console panel clips not being engaged correctly. Most of
these incidents are repaired by pushing up on the console at the clip locations until the clips engage.
In addition look for:
1. Loose harness or harness connectors.
2. Front console map/reading lamp lens loose.
3. Loose screws at console attachment points.
SEATS
When isolating seat noise it's important to note the position the seat is in and the load placed on the seat when
the noise is present. These conditions should be duplicated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. The rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of these incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted underhood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.
Page 2340 of 2896
MA-6
GENERAL MAINTENANCE
Revision: June 20062007 Versa
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).Accelerator pedalCheck the pedal for smooth operation and make sure the pedal does not catch
or require uneven effort. Keep the floor mats away from the pedal.—
Clutch pedalMake sure the pedal operates smoothly and check that it has the proper free
play.MA-22
BrakesCheck that the brake does not pull the vehicle to one side when applied. —
Brake pedal and
boosterCheck the pedal for smooth operation and make sure it has the proper distance
under it when depressed fully. Check the brake booster function. Be sure to
keep floor mats away from the pedal.BR-6, "
Inspection and
Adjustment" and BR-19,
"On-board Inspection"
Parking brakeCheck that the lever has the proper travel and make sure that the vehicle is held
securely on a fairly steep hill when only the parking brake is applied.PB-4, "INSPECTION"
Automatic transaxle
“Park” mechanismCheck that the lock release button on the selector lever operates properly and
smoothly. On a fairly steep hill check that the vehicle is held securely with the
selector lever in the “P” position without applying any brakes.—
CVT P (Park) position
mechanismOn a fairly steep hill check that the vehicle is held securely with the selector
lever in the “P” position without applying any brakes.— ItemReference page
ItemReference page
Windshield
washer fluidCheck that there is adequate fluid in the tank. —
Engine coolant
levelCheck the coolant level when the engine is cold.CO-8, "
LEVEL CHECK"
A/C condenser,
radiator and
hosesCheck the front of the condenser and radiator and clean off any dirt, insects,
leaves, etc., that may have accumulated. Make sure the radiator hoses have no
cracks, deformation, deterioration or loose connections.—
Brake and clutch
fluid levelsMake sure that the brake and clutch fluid levels are between the “MAX” and “MIN”
lines on the reservoirs.BR-9, "
CHECKING BRAKE
FLUID LEVEL" and MA-22,
"Checking Clutch Fluid
Level and Leaks"
BatteryCheck the fluid level in each cell. It should be between the “MAX” and “MIN” lines.
Vehicles operated in high temperatures or under severe conditions require fre-
quent checks of the battery fluid level.—
Engine drive beltsMake sure that no belt is frayed, worn, cracked or oily.MA-13
Engine oil levelCheck the level on the dipstick after parking the vehicle on a level spot and turning
off the engine.LU-5, "ENGINE OIL
LEVEL"
Automatic tran-
saxle fluid levelCheck the level on the dipstick after putting the selector lever in “P” with the
engine idling.MA-20 and MA-22
Exhaust systemMake sure there are no loose supports, cracks or holes. If the sound of the
exhaust seems unusual or there is a smell of exhaust fumes, immediately locate
the trouble and correct it.MA-20
UnderbodyThe underbody is frequently exposed to corrosive substances such as those used
on icy roads or to control dust. It is very important to remove these substances,
otherwise rust will form on the floor pan, frame, fuel lines and around the exhaust
system. At the end of winter, the underbody should be thoroughly flushed with
plain water, being careful to clean those areas where mud and dirt can easily
accumulate.—
Fluid leaksCheck under the vehicle for fuel, oil, water or other fluid leaks after the vehicle has
been parked for a while. Water dripping from the air conditioner after use is nor-
mal. If you should notice any leaks or gasoline fumes are evident, check for the
cause and correct it immediately.—
Page 2347 of 2896
ENGINE MAINTENANCE
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ENGINE MAINTENANCE PFP:00100
Drive BeltsELS001XU
Checking Drive BeltsELS001XV
WA RN ING:
Be sure to perform this step when the engine is stopped.
Make sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use
range (A).
NOTE:
Check the drive belt auto-tensioner indication when the engine is cold.
When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the
figure.
Visually check entire drive belt for wear, damage or cracks.
If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
Tension AdjustmentELS001XW
Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Changing Engine CoolantELS001XX
WA RN ING:
To avoid being scalded, do not change engine coolant when engine is hot.
Wrap a thick cloth around radiator 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.
Be careful not to allow engine coolant to contact drive belt.
DRAINING ENGINE COOLANT
1. Open radiator drain plug (1) at the bottom of radiator, and then
remove radiator cap.
Vehicle front
When drain all of engine coolant in the system, open water
drain plug on cylinder block. Refer to EM-77, "
CYLINDER
BLOCK" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belt.
2. Remove reservoir tank as necessary, and drain engine coolant and clean reservoir tank before installing.
Refer to CO-11, "
RADIATOR" .
3. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
1. Alternator 2. Drive belt auto–tensioner 3. Crankshaft pulley
4.A/C compressor (models with A/C)
Idler pulley (models without A/C)5. Water pump 6. Drive belt
A. Possible use range B. Range when new drive belt is installed C. Indicator
PBIC3137J
PBIC3799E
Page 2348 of 2896
MA-14
ENGINE MAINTENANCE
Revision: June 20062007 Versa
If contaminated, flush the engine cooling system. Refer to MA-15, "FLUSHING COOLING SYSTEM" .
REFILLING ENGINE COOLANT
1. Install reservoir tank if removed. Refer to CO-11, "RADIATOR" .
2. Install radiator drain plug.
If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-77, "CYLIN-
DER BLOCK" .
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring. Refer to CO-11, "
Components" .
3. Make sure that each hose clamp has been firmly tightened.
4. Remove air duct assembly. Refer to EM-16, "
AIR CLEANER AND AIR DUCT" .
5. Disconnect heater hose (1) at position ( ) as shown.
Front
Enhance heater hose as high as possible.
6. Fill radiator and reservoir tank to specified level.
Pour engine coolant through engine coolant filler neck
slowly of less than 2 (2 1/8 US qt, 1-3/4 lmp qt) a minute
to allow air in system to escape.
Use NISSAN Genuine Engine Coolant or equivalent
mixed with water (distilled or demineralized). Fill cooling
system to specification. Refer to MA-11, "
RECOM-
MENDED FLUIDS AND LUBRICANTS".
When engine coolant overflows disconnected heater hose,
connect heater hose, and continue filling the engine coolant, if
heater hose is disconnected.
7. Install radiator cap.
8. Install air duct assembly. Refer to EM-16, "
AIR CLEANER AND AIR DUCT" .
9. Warm up until opening thermostat. Standard for warming-up time is approximately 10 minutes at 3,000
rpm.
Make sure thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.
CAUTION:
Watch water temperature gauge so as not to overheat the engine.
10. Stop engine and cool down to less than approximately 50°C (122°F).
Cool down using fan to reduce the time.
If necessary, refill radiator up to filler neck with engine coolant.
11. Refill reservoir tank to “MAX” level line with engine coolant.
12. Repeat steps 6 through 10 two or more times with radiator cap installed until engine coolant level no
longer drops.
13. Check cooling system for leaks with engine running.
14. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000
rpm with heater temperature controller set at several position between “COOL” and “WARM”.
Sound may be noticeable at heater unit.
15. Repeat step 14 three times.
16. If sound is heard, bleed air from cooling system by repeating steps 6 through 10 until engine coolant level
no longer drops.
PBIC3802E
SM A18 2B