radiator cap NISSAN X-TRAIL 2005 Service Repair Manual

GI-4
PRECAUTIONS

General PrecautionsEAS000FQ

Do not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refriger-
ant gas, etc. When working in a pit or other enclosed area, be
sure to properly ventilate the area before working with hazard-
ous materials.
Do not smoke while working on the vehicle.

Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting before working
on the vehicle.
These operations should be done on a level surface.

When removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.

Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.

If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.

To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.

Dispose of 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.
SGI285
SGI231
SEF289H
SGI233

CATALYST
EM-149
[YD22DDTi]
C
D
E
F
G
H
I
J
K
L
MA
EM

CATALYSTPFP:20905
Removal and InstallationEBS00LRG
REMOVAL
1. Remove engine undercover.
2. Drain engine coolant. Refer to CO-32, "
Changing Engine Coolant" .
3. Remove radiator hose (upper and lower). Refer to CO-35, "
RADIATOR" .
4. Remove cooling fan assembly. Refer to CO-37, "
DISASSEMBLY AND ASSEMBLY" .
5. Remove radiator mounting bracket and radiator. Refer to CO-35, "
Removal and Installation" .
6. Remove water inlet pipe. Refer to CO-45, "
THERMOSTAT AND WATER PIPING" .
7. Remove catalyst insulators.
8. Remove exhaust front tube. Refer to EX-2, "
EXHAUST SYSTEM" .
9. Remove catalyst.
CAUTION:
Do not disassemble.
NOTE:
Install two locking pins into both sides of the catalyst. Be careful not to confuse locking pins with insulator
mounting bolts.
1. Catalyst insulator 2. Gasket 3. Catalyst
4. Locking pin 5. Gusset 6. Gasket cap
7. Catalyst rear diffuser 8. Turbocharger insulator
PBIC2670E
Catalyst locking pin : Flange bolt (black)

CO-1
ENGINE COOLING SYSTEM
B ENGINE
CONTENTS
C
D
E
F
G
H
I
J
K
L
M
SECTION CO
A
CO

ENGINE COOLING SYSTEM
QR
PRECAUTIONS .......................................................... 3
Precautions for Liquid Gasket .................................. 3
LIQUID GASKET APPLICATION PROCEDURE ..... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
Commercial Service Tools ........................................ 4
OVERHEATING CAUSE ANALYSIS .......................... 5
Troubleshooting Chart .............................................. 5
COOLING SYSTEM .................................................... 7
Cooling Circuit .......................................................... 7
System Chart ........................................................... 8
ENGINE COOLANT .................................................... 9
Inspection ................................................................. 9
LEVEL CHECK ..................................................... 9
LEAK CHECK ....................................................... 9
Changing Engine Coolant ........................................ 9
DRAINING ENGINE COOLANT ........................... 9
REFILLING ENGINE COOLANT ........................ 10
FLUSHING COOLING SYSTEM ......................... 10
RADIATOR ................................................................ 12
Removal and Installation ........................................ 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13
INSPECTION AFTER INSTALLATION ............... 13
Checking Radiator Cap .......................................... 13
Checking Radiator .................................................. 13
RADIATOR (ALUMINUM TYPE) .............................. 15
Disassembly and Assembly ................................... 15
PREPARATION ................................................... 15
DISASSEMBLY ................................................... 15
ASSEMBLY ......................................................... 16
INSPECTION ...................................................... 18
COOLING FAN ......................................................... 19
Removal and Installation ........................................ 19
REMOVAL ........................................................... 19INSTALLATION ................................................... 19
Disassembly and Assembly .................................... 20
DISASSEMBLY ................................................... 20
INSPECTION AFTER DISASSEMBLY ................ 20
ASSEMBLY ......................................................... 20
WATER PUMP .......................................................... 21
Removal and Installation ........................................ 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 22
INSTALLATION ................................................... 22
INSPECTION AFTER INSTALLATION ................ 22
THERMOSTAT AND WATER CONTROL VALVE .... 23
Removal and Installation ........................................ 23
REMOVAL ........................................................... 23
INSPECTION AFTER REMOVAL ....................... 24
INSTALLATION ................................................... 24
INSPECTION AFTER INSTALLATION ................ 24
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 25
Standard and Limit .................................................. 25
CAPACITY ........................................................... 25
RADIATOR .......................................................... 25
THERMOSTAT .................................................... 25
WATER CONTROL VALVE ................................. 25
Tightening Torque ................................................... 25
YD22DDTi
PRECAUTIONS ........................................................ 26
Precautions For Liquid Gasket ............................... 26
LIQUID GASKET APPLICATION PROCEDURE ... 26
PREPARATION ......................................................... 27
Special Service Tools ............................................. 27
Commercial Service Tools ...................................... 27
OVERHEATING CAUSE ANALYSIS ........................ 28
Troubleshooting Chart ............................................ 28
COOLING SYSTEM .................................................. 30
Cooling Circuit ........................................................ 30
System Chart .......................................................... 31
ENGINE COOLANT .................................................. 32
Inspection ............................................................... 32

CO-2 LEVEL CHECK .................................................... 32
CHECKING RADIATOR SYSTEM FOR LEAKS ... 32
Changing Engine Coolant ....................................... 32
DRAINING ENGINE COOLANT .......................... 32
REFILLING ENGINE COOLANT ......................... 33
FLUSHING COOLING SYSTEM ......................... 34
RADIATOR ................................................................ 35
Removal and Installation ........................................ 35
REMOVAL ........................................................... 35
INSTALLATION .................................................... 35
INSPECTION AFTER INSTALLATION ................ 35
Checking Radiator Cap .......................................... 36
Checking Radiator .................................................. 36
COOLING FAN .......................................................... 37
Removal and Installation ........................................ 37
REMOVAL ........................................................... 37
INSTALLATION .................................................... 37
DISASSEMBLY AND ASSEMBLY ....................... 37
RADIATOR (ALUMINUM TYPE) ............................... 39
Disassembly and Assembly .................................... 39
PREPARATION ................................................... 39
DISASSEMBLY ................................................... 39
ASSEMBLY ......................................................... 40
INSPECTION ....................................................... 42WATER PUMP ........................................................... 43
Removal and Installation ......................................... 43
REMOVAL ............................................................ 43
INSPECTION AFTER REMOVAL ........................ 44
INSTALLATION .................................................... 44
INSPECTION AFTER INSTALLATION ................ 44
THERMOSTAT AND WATER PIPING ....................... 45
Removal and Installation ......................................... 45
REMOVAL ............................................................ 45
INSPECTION AFTER REMOVAL ........................ 46
INSTALLATION .................................................... 46
INSPECTION AFTER INSTALLATION ................ 46
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 47
Standard and Limit .................................................. 47
CAPACITY ........................................................... 47
THERMOSTAT ..................................................... 47
RADIATOR ........................................................... 47
Tightening Torque ................................................... 47

CO-4
[QR]
PREPARATION

PREPARATIONPFP:00002
Special Service ToolsEBS00KOC
Commercial Service ToolsEBS011T8
Tool number
Tool nameDescription
EG17650301
Radiator cap tester adapterAdapting radiator cap tester to radiator cap
and 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
WS39930000
Tube presserPressing the tube of liquid gasket
S-NT564
S-NT224
S-NT225
S-NT052
Tool nameDescription
Radiator cap tester Checking radiator and radiator cap
PBIC1982E

OVERHEATING CAUSE ANALYSIS
CO-5
[QR]
C
D
E
F
G
H
I
J
K
L
MA
CO

OVERHEATING CAUSE ANALYSISPFP:00012
Troubleshooting ChartEBS00KOD
Symptom Check items
Cooling sys-
tem parts
malfunctionPoor heat transferWater pump malfunction Worn or loose drive belt
— Thermostat and water con-
trol valve 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-
ate
Fan assembly — High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud — — —
Improper engine coolant
mixture ratio—— —
Poor engine coolant quality — Engine coolant viscosity —
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

ENGINE COOLANT
CO-9
[QR]
C
D
E
F
G
H
I
J
K
L
MA
CO

ENGINE COOLANTPFP:KQ100
InspectionEBS00KOG
LEVEL CHECK

Check if the reservoir tank engine coolant level is within “MIN” to
“MAX” range when engine is cool.

Adjust engine coolant level as necessary.
LEAK CHECK

To check for leakage, apply pressure to the cooling system with
a radiator cap tester (commercial service tool) and a radiator
cap tester adapter (special service tool).
WARNING:
Do not remove radiator cap when engine is hot. Serious
burns could occur from high-pressure engine coolant
escaping from radiator.
CAUTION:
Higher test pressure than specified may cause radiator
damage.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.

If anything is found, repair or replace damaged parts.
Changing Engine CoolantEBS00KOH
WARNING:

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. Remove RH and LH undercovers.
2. Open radiator drain plug at the bottom of radiator, and then
remove radiator cap.
When drain all of engine coolant in the system, open water drain plug on cylinder block. Refer to
EM-94, "
ASSEMBLY" .
3. Remove reservoir tank as necessary, and drain engine coolant and clean reservoir tank before installing.
SMA412B
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2 , 23 psi)
SLC134B
PBIC2250E

CO-10
[QR]
ENGINE COOLANT

4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to CO-10, "
FLUSHING COOLING SYSTEM" .
REFILLING ENGINE COOLANT
1. Install reservoir tank if removed, and radiator drain plug.
CAUTION:
Be sure to clean drain plug and install with new O-ring.

If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-89, "CYLIN-
DER BLOCK" .
2. Make sure that each hose clamp has been firmly tightened.
3. Fill radiator and reservoir tank to specified level.

Pour engine coolant through engine coolant filler neck
slowly of less than 2 (1-3/4 lmp qt) a minute to allow air
in system to escape.

Use Genuine NISSAN Anti-freeze Coolant or equivalent
mixed with water (distilled or demineralized). Refer to
MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS".
4. Install radiator cap.
5. Warm up until opening thermostat and water control valve. 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.
6. Stop the 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.
7. Refill reservoir tank to “MAX” level line with engine coolant.
8. Repeat steps 3 through 6 two or more times with radiator cap installed until the engine coolant level no
longer drops.
9. Check cooling system for leaks with the engine running.
10. Warm up the engine, and check for sound of engine coolant flow while running the 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.
11. Repeat step 10 three times.
12. If sound is heard, bleed air from cooling system by repeating step 3 through 6 until the engine coolant
level no longer drops.
FLUSHING COOLING SYSTEM
1. Install reservoir tank if removed, and radiator drain plug.Engine coolant capacity
(with reservoir tank at “MAX” level)
: Approx. 7.1 (6-1/4 lmp qt)
SMA182B
Reservoir tank capacity (at “MAX” level)
: 0.7 (5/8 lmp qt)
SMA412B

ENGINE COOLANT
CO-11
[QR]
C
D
E
F
G
H
I
J
K
L
MA
CO

CAUTION:
Be sure to clean drain plug and install with new O-ring.

If water drain plug on cylinder block is removed, close and tighten it. Refer to EM-89, "CYLIN-
DER BLOCK" .
2. Fill radiator and reservoir tank with water and reinstall radiator cap.
3. Run the engine and warm it up to normal operating temperature.
4. Rev the engine two or three times under no-load.
5. Stop the engine and wait until it cools down.
6. Drain water from the system. Refer to CO-9, "
DRAINING ENGINE COOLANT" .
7. Repeat steps 1 through 6 until clear water begins to drain from radiator.

CO-12
[QR]
RADIATOR

RADIATORPFP:21400
Removal and InstallationEBS00KOI
WARNING:
Do not remove radiator cap when the engine is hot. Serious burns could occur from high-pressure
engine coolant escaping from radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter of a
turn to release built-up pressure. Carefully remove radiator cap by turning it all the way.
REMOVAL
1. Remove RH and LH undercovers.
2. Drain engine coolant. Refer to CO-9, "
Changing Engine Coolant" .
CAUTION:

Perform this step when engine is cold.

Do not spill engine coolant on drive belt.
3. Remove air duct (inlet) and air duct assembly. Refer to EM-16, "
AIR CLEANER AND AIR DUCT" .
4. Disconnect harness connector from fan motor, and move it aside.
5. Disconnect radiator hoses (upper and lower).
6. Remove A/T fluid cooler hoses. (A/T models)

Install blind plug to avoid leakage of A/T fluid.
7. Remove radiator mounting brackets.
8. Remove radiator and radiator cooling fan assembly.
CAUTION:
Do not damage or scratch radiator core when removing.
1. Reservoir tank 2. Reservoir tank cap 3. Reservoir tank hose
4. Radiator mounting bracket 5. Mounting rubber (upper) 6. Radiator cap
7. Radiator 8. O-ring 9. Radiator drain plug
10. Mounting rubber (lower) 11. A/T fluid cooler hose 12. Radiator hose (lower)
13. Radiator hose (upper) 14. Bracket 15. Radiator cooling fan assembly
PBIC3640E