radiator NISSAN X-TRAIL 2003 Electronic Owner's Manual

WATER PUMP
CO-19
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WATER P UM PPFP:21020
Removal and InstallationEBS009SJ
WA RN ING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
REMOVAL
Water Pump Removal
1. Drain coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
CAUTION:
Perform when the engine is cold.
2. Remove the following parts.
lEngine under cover
lAlternator, water pump and air compressor belt
Refer to drive beltEM-13, "
Removal and Installation".
3. Remove water pump.
lCoolant will leak from the cylinder block, so have a receptacle ready below.
CAUTION:
lHandle the water pump vane so that it does not contact any other parts.
lWater pump cannot be disassembled and should be replaced as a unit.
Water Pump Housing Removal
1. Perform step 1 and 2 of “Water Pump Removal”.
2. Remove alternator.
3. Remove oil level gauge.
CAUTION:
Plug the oil level gauge guide opening to prevent oil pan from entering foreign materials.
4. Remove bolts mounting water pipe.
5. Remove water pump housing.
Water Pipe Removal
1. Remove water pump housing.
KBIA0154E
1 Water pump 2 Gasket 3 Water pump housing
4 Water pipe

CO-20
[QR20DE]
WATER PUMP
2. Remove exhaust manifold and three way catalyst assembly. Refer toEM-22, "EXHAUST MANIFOLD
AND THREE WAY CATALYST".
3. Remove water pipe.
INSPECTION AFTER REMOVAL
lVisually check that there is no significant dirt or rusting on the
water pump body and vane.
lCheck that there is no looseness in the vane shaft, and that it
turns smoothly when rotated by hand.
lIf there are any unusualness, replace the water pump assembly.
INSTALLATION
lInstall in the reverse order of removal
lWhen inserting water pipe end to cylinder block, apply a neutral detergent to o-ring. Then insert it immedi-
ately.
INSPECTION AFTER INSTALLATION
lCheck for coolant leaks using radiator cap tester. Refer toCO-9, "LEAK CHECK".
KBIA0155E

THERMOSTAT AND WATER CONTROL VALVE
CO-21
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THERMOSTAT AND WATER CONTROL VALVEPFP:21200
Removal and InstallationEBS009SK
WA RN ING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
REMOVAL
Thermostat Removal
1. Drain engine coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
CAUTION:
Perform when the engine cold.
2. Disconnect radiator lower hose at water inlet side.
3. Remove water inlet and thermostat.
Water Control Valve Removal
1. Drain engine coolant. Refer toCO-9, "DRAINING ENGINE COOLANT".
2. Disconnect upper radiator hose, heater pipe and heater hose at water outlet side.
3. Remove water outlet.
4. Remove water control valve.
PBIC0239E
1 Thermostat 2 Water inlet 3 Water control valve
4 Water outlet 5 Heater hose 6 Engine coolant temperature sensor
7Heaterpipe

SERVICE DATA AND SPECIFICATIONS (SDS)
CO-23
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
CapacityEBS009SL
ThermostatEBS009SM
Water Control ValveEBS009SN
RadiatorEBS009SO
Unit:kPa(bar,kg/cm2,psi)
Tightening TorqueEBS009SP
Unit: N·m (kg-m, ft-lb) Nm(kg-m, in-lb)* Coolant capacity [With reservoir tank (MAX level)]
Approximately 7.1 (6-1/4 Imp qt)
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Valve liftMore than 8 mm/ 95°C (0.315 in/203°F)
Valve opening temperature 93.5 - 96.5°C (200 - 206°F)
Valve lift More than 8 mm/108°C (0.315 in/226°F)
Cap relief pressureStandard 78 - 98 (0.78 - 0.98, 0.8 -1.0, 11- 14)
Limit 59 (0.59, 0.6, 9)
Leakage test pressure 157 (1.57, 1.6, 23)
Radiator mounting bracket
Radiator fan assembly
Fan
Fan motor3.8 - 4.5 (0.39 - 0.46, 34 - 39)*
3.8 - 4.5 (0.39 - 0.46, 34 - 39)*
2.9 - 3.9 (0.30 - 0.40, 26 - 34)*
3.9 - 4.9 (0.40 - 0.50, 35 - 43)*
Water pum p
Water pump housing
Water inlet
Water outlet
Water pipet
Hater pip
Water temperature sensor20.8 - 28.2 (2.1 - 2.9, 16- 20)
20.8 - 28.2 (2.1 - 2.9, 16 - 20)
20.8 - 28.2 (2.1 - 2.9, 16- 20)
20.8 - 28.2 (2.1 - 2.9, 16 - 20)
20.8 - 28.2 (2.1 - 2.9, 16 - 20)
20.8 - 28.2 (2.1 - 2.9, 16 - 20)
19.6 - 29.4 (2.0 - 3.0, 14- 22)

PREPARATION
CO-25
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PREPARATIONPFP:00002
Special Service ToolsEBS00BAV
Tool number
Tool nameDescription
WS39930000
Tube pressurePressing the tube of liquid gasket
EG17650301
Radiator cap tester adapterAdapting radiator cap tester to radiator filler
neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
KV99103510
Radiator plate pliers AInstalling radiator upper and lower tanks
KV99103520
Radiator plate pliers BRemoving radiator upper and lower tanks
S-NT052
S-NT564
S-NT224
S-NT225

CO-26
[YD22DDTi]
OVERHEATING CAUSE ANALYSIS
OVERHEATING CAUSE ANALYSIS
PFP:00012
Troubleshooting ChartEBS00BAW
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

OVERHEATING CAUSE ANALYSIS
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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
—
Installed large fog lamp Symptom Check items

CO-30
[YD22DDTi]
ENGINE COOLANT
ENGINE COOLANT
PFP:KQ100
InspectionEBS00BAY
LEVEL CHECK
lCheck if the reservoir tank coolant level within MIN to MAX when
engine is cool.
lAdjust coolant if too much or too little.
LEAK CHECK
lTo check for leakage, apply pressure to the cooling system with
atester.
WAR NIN G:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure coolant escaping from
the radiator.
CAUTION:
Higher pressure than specified may cause radiator damage.
Changing Engine CoolantEBS00BAZ
WAR NIN G:
lTo avoid being scalded, never change the coolant when the engine is hot.
lWrap a thick cloth around 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.
DRAINING ENGINE COOLANT
1. Open radiator drain plug at the bottom of radiator, and remove
radiator cap.
lBe careful not to allow coolant to contact drive belts.
lCover the exhaust tube heat shield to prevent from splashing
coolant.
2. Remove reservoir tank, drain coolant, then clean reservoir tank.
SMA412B
Testing pressure
: 157 kPa (1.57bar 1.6 kg/cm2,23psi)
SLC134B
PBIC0236E

ENGINE COOLANT
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3. Open drain plugs on cylinder block and air relief plug.
4. Check drained coolant for contaminants such as rust, corrosion
or discoloration.
If contaminated, flush engine cooling system. Refer toCO-32,
"FLUSHING COOLING SYSTEM".
REFILLING ENGINE COOLANT
1. Install reservoir tank, radiator drain plug and cylinder block drain plug.
Apply sealant to the thread of cylinder block drain plug.
lUse Genuine Liquid Gasket or equivalent.
2. Fill radiator slowly with coolant until coolant spills from the air
relief plugs, then install air relief plugs.
CAUTION:
If the filling rate is too fast, this could lead to air being
mixed in the coolant. Be sure to fill the coolant slowly
according to the rate indicated above.
lReplace the copper washer of the air bleeding plug.
lUse genuine Nissan anti-freeze coolant or equivalent mixed with water (distilled or demineralized).
Refer toMA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS".
lPour coolant through coolant filler neck slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.
SBIA0129E
SBIA0130E
: 7.8 - 11.8 N·m (0.8 -1.2 kg-m , 69 - 104 in-lb)
Air relief plug :
: 6.7 - 7.9 N·m (0.68 - 0.81 kg-m, 59 - 70 in-lb)
Engine coolant capacity (With reservoir tank):
9.5 ( 8-3/8 Imp qt)
SMA182B
Reservoir tank : 0.6 (1/2 lmp qt )

CO-32
[YD22DDTi]
ENGINE COOLANT
3. Fill reservoir tank to specified level.
4. Warm up engine to normal operating temperature without radia-
tor cap installed.
lIf coolant overflows radiator filler hole, install filler cap.
5. Run engine at 3,000 rpm for 10 seconds and return to idle speed
with radiator cap installed.
lRepeat two or three times.
Watch coolant temperature gauge so as not to overheat the
engine.
6. Stop engine and cool down to less than approximately
50°C(122°F).
lCool down using a fan to reduce the time.
lIf necessary, refill radiator up to filler neck with coolant.
7. Refill reservoir tank to MAX level line with coolant.
8. Repeat steps 5 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 temperature controller set at several position between COOL and WARM.
lSound may be noticeable at heater unit.
11. If sound is heard, bleed air from cooling system by repeating steps 5 through 7 until coolant level no
longer drops.
lClean excess coolant from engine.
FLUSHING COOLING SYSTEM
1. Fill radiator with water until water spills from the air relief hole, then close air relief flag. Fill radiator and
reservoir tank with water and reinstall radiator cap.
2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down.
5. Drain water.
6. Repeat steps 1 through 5 until clear water begins to drain from radiator.
SMA412B