ENGINE LUBRICATION &

COOLING SYSTEMS GI

SECTION LC MA

EM

EC

CONTENTS FE

ENGINE LUBRICATION SYSTEM..................................2 CHECKING RADIATOR CAP ....................................12

CL
Precautions ..................................................................2 CHECKING COOLING SYSTEM FOR LEAKS ............13
LIQUID GASKET APPLICATION PROCEDURE ............2 Water Pump ...............................................................13 MT
Preparation ..................................................................2 REMOVAL AND INSTALLATION ...............................13
SPECIAL SERVICE TOOLS ........................................2 INSPECTION ...........................................................14
Lubrication Circuit ........................................................3 Thermostat.................................................................15 AT
Oil Pressure Check......................................................4 REMOVAL AND INSTALLATION ...............................15
Oil Pump ......................................................................4 INSPECTION ...........................................................16
REMOVAL AND INSTALLATION .................................4 Radiator .....................................................................17 AX
DISASSEMBLY AND ASSEMBLY................................5 COMPONENTS .......................................................17
INSPECTION .............................................................6 Cooling Fan ...............................................................18
REGULATOR VALVE INSPECTION ............................6 COMPONENTS .......................................................18 SU
Changing Engine Oil....................................................7 CONTROL SYSTEM ................................................18
Changing Oil Filter.......................................................8 Changing Engine Coolant..........................................18
Service Data and Specifications (SDS).......................9 - DRAINING ENGINE COOLANT - ............................18 BR
OIL PRESSURE CHECK ............................................9 - REFILLING ENGINE COOLANT - ...........................19
OIL PUMP INSPECTION ............................................9 - FLUSHING COOLING SYSTEM -............................20
Radiator (Aluminum type)..........................................21 ST
REGULATOR VALVE INSPECTION ............................9
OIL CAPACITY ..........................................................9 PREPARATION .......................................................21
ENGINE COOLING SYSTEM........................................10 DISASSEMBLY ........................................................21
ASSEMBLY .............................................................22
RS
Precautions ................................................................10
INSPECTION ...........................................................24
LIQUID GASKET APPLICATION PROCEDURE ..........10
Overheating Cause Analysis .....................................25
Preparation ................................................................10 BT
SPECIAL SERVICE TOOLS ......................................10
Service Data and Specifications (SDS).....................26
THERMOSTAT ........................................................26
Cooling Circuit ...........................................................11
RADIATOR ..............................................................26 HA
System Check............................................................11
COOLANT CAPACITY ..............................................26
CHECKING COOLING SYSTEM HOSES ...................11
CHECKING RADIATOR ............................................12
SC

EL

IDX
 ENGINE LUBRICATION SYSTEM
Precautions

Precautions
LIQUID GASKET APPLICATION PROCEDURE NJLC0001
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
I For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
I For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.

AEM080

Preparation
SPECIAL SERVICE TOOLS NJLC0002

Tool number
Description
Tool name

ST25051001 Measuring oil pressure

Oil pressure gauge Maximam measuring rang
2,452 kPa (24.5 bar, 25 kg/cm2, 356 psi)

NT050

ST25052000 Adapting oil pressure gauge to cylinder block

Hose

NT559

KV10115801 Removing oil filter

Oil filter wrench

NT772

WS39930000 Pressing the tube of liquid gasket

Tube presser

NT052

LC-2
ENGINE LUBRICATION SYSTEM
Lubrication Circuit

Lubrication Circuit NJLC0003

GI

MA

EM

EC

FE

CL

MT

AT

SLC561B
AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

SLC562B

LC-3
 ENGINE LUBRICATION SYSTEM
Oil Pressure Check

Oil Pressure Check NJLC0004

WARNING:
I Be careful not to burn yourself, as the engine and oil may
be hot.
I For M/T models, put gearshift lever in Neutral “N” posi-
tion. For A/T models, put selector lever in Park “P” posi-
tion.
1. Check oil level.
2. Remove oil pressure switch.

SEM853F

3. Install pressure gauge.

4. Start engine and warm it up to normal operating temperature.
5. Check oil pressure with engine running under no-load.
QG13DE (Without three way catalyst)
Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi)

Idle speed More than 94.1 (0.94, 0.96, 13.6)

2,000 More than 287.4 (2.87, 2.93, 41.7)

SLC926-A 6,000 More than 438.8 (4.39, 4.48, 63.6)

Except for QG13DE (Without three way catalyst)

Engine speed Approximate discharge pressure
rpm kPa (bar, kg/cm2, psi)

Idle speed More than 93.2 (0.93, 0.95, 13.5)

2,000 More than 273.2 (2.73, 2.79, 39.6)

6,000 More than 356.6 (3.57, 3.64, 51.7)

I If difference is extreme, check oil passage and oil pump

for oil leaks.
6. After the inspections, install the oil pressure switch as follows.
a. Remove the old sealant adhering to the switch and engine.
b. Apply Genuine Liquid Gasket or equivalent to the thread and
tighten.
: 12.3 - 17.2 N·m (1.25 - 1.75 kg-m, 9 - 12 ft-lb)

Oil Pump
REMOVAL AND INSTALLATION NJLC0005
I Make sure that O-ring is fitted properly.
1. Drain engine oil.
2. Remove drive belts. Refer to EM-17, “DRIVE BELTS”.
3. Remove oil pan. Refer to EM-20, “OIL PAN”.
4. Remove oil strainer.
5. Remove front cover. Refer to EM-23, “TIMING CHAIN”.
6. Install front cover.
7. Reinstall parts in the reverse order of removal.
LC-4
 ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)
DISASSEMBLY AND ASSEMBLY NJLC0006

GI

MA

EM

EC

FE

CL
SLC563B

1. Oil pump cover 4. Front cover 7. Regulator valve spring MT

2. Inner rotor 5. Oil strainer 8. Washer
3. Outer rotor 6. Regulator valve 9. Regulator valve plug
AT
I When installing oil pump, apply engine oil to rotors.
AX

SU

BR
I Install inner rotor and outer rotor with the punched marks
on the oil pump cover side. ST

RS

BT

HA
JLC307B

SC

EL

IDX

LC-5
 ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)
INSPECTION NJLC0007
Using a feeler gauge, check the following clearances.
Standard clearance:
Unit: mm (in)

Body to outer rotor radial clearance 1 0.114 - 0.200 (0.0045 - 0.0079)

Inner rotor to outer rotor tip clearance

Below 0.18 (0.0071)
2

Body to inner rotor clearance 3 0.030 - 0.070 (0.0012 - 0.0028)

SEM855F
Body to outer rotor axial clearance 4 0.030 - 0.090 (0.0012 - 0.0035)

Inner rotor to brazed portion of hous-

0.045 - 0.091 (0.0018 - 0.0036)
ing clearance 5

SEM856F

I If it exceeds the standard, replace front cover assembly.

SEM857FA

REGULATOR VALVE INSPECTION NJLC0008

1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and valve
spring.
3. Coat regulator valve with engine oil.
Check that it falls smoothly into the valve hole by its own
weight.
If damaged, replace front cover assembly.

SLC986AA

LC-6
ENGINE LUBRICATION SYSTEM
Oil Pump (Cont’d)
4. Check regulator valve to front cover clearance.
Clearance 6:
Standard GI
0.040 - 0.097 mm (0.0016 - 0.0038 in)
If it exceeds the standard, replace front cover assembly. MA

EM

SLC101B

Changing Engine Oil NJLC0035

WARNING: EC
I Be careful not to burn yourself, as the engine oil is hot.
I Prolonged and repeated contact with used engine oil may
cause skin cancer; try to avoid direct skin contact with FE
used oil. If skin contact is made, wash thoroughly with
soap or hand cleaner as soon as possible.
1. Warm up engine, and check for oil leakage from engine com- CL
ponents.
2. Stop engine and wait more than 10 minutes.
SMA915C
MT
3. Loosen oil filler cap, and then remove drain plug.
4. Drain engine oil.
5. Install drain plug with new washer. Refer to EM-20, “OIL PAN”. AT
CAUTION:
I Be sure to clean drain plug and install with new washer.
Drain plug:
AX
: 29.4 - 39.2 N·m (3.0 - 4.0 kg-m, 22 - 29 ft-lb)
6. Refill with new engine oil. SU
Engine oil specification and viscosty:
Refer to MA-8, “RECOMMENDED FLUIDS AND LUBRI-
CANTS”. BR
SMA390C
Refill oil capacity (Approximate):
Unit:  (Imp qt)
ST
With oil filter change 2.7 (2-3/8)
Drain and refill
Without oil filter change 2.5 (2-1/4)
RS
Dry engine (engine overhaul) 3.1 (2-3/4)

CAUTION: BT
I The refill capacity changes depending on the oil tempera-
ture and drain time, use these values as a reference and
be certain to check with the dipstick when changing the HA
oil.
7. Check oil level.
8. Start engine and check area around drain plug and oil filter for SC
oil leakage.
9. Run engine for a few minutes, then turn it off. After several EL
minutes, check oil level.

IDX

LC-7
 ENGINE LUBRICATION SYSTEM
Changing Oil Filter

Changing Oil Filter NJLC0010

Oil filter is a small, full-flow cartridge type and is provided with a
relief valve.
I Use oil filter wrench (SST: KV10115801) for removing oil
filter.

ALC094

1. Remove oil filter with oil filter wrench (SST).

WARNING:
Be careful not to burn yourself, as the engine and the engine
oil are hot.

SLC275B

2. Clean oil filter mounting surface on cylinder block. Coat rubber

seal of new oil filter with engine oil.

SMA010

3. Screw in oil filter until a slight resistance is felt, then tighten an

additional 2/3 turn.
4. Add engine oil.
Refer to “Changing Engine Oil”.
I Clean excess oil from engine.

SMA229B

LC-8
 ENGINE LUBRICATION SYSTEM
Service Data and Specifications (SDS)

Service Data and Specifications (SDS)

OIL PRESSURE CHECK =NJLC0011
GI
Approximate discharge pressure
Engine speed kPa (bar, kg/cm2, psi)
rpm
QG13DE (With three way catalyst) Except for QG13DE (With three way catalyst)
MA
Idle speed More than 94.1 (0.94, 0.96, 13.6) More than 93.2 (0.93, 0.95, 13.5)

2,000 More than 287.4 (2.87, 2.93, 41.7) More than 273.2 (2.73, 2.79, 39.6)
EM
6,000 More than 438.8 (4.39, 4.48, 63.6) More than 356.6 (3.57, 3.64, 51.7)

OIL PUMP INSPECTION NJLC0013

Unit: mm (in)
EC
Body to outer rotor radial clearance 0.114 - 0.200 (0.0045 - 0.0079)

Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)

FE
Body to inner rotor clearance 0.030 - 0.070 (0.0012 - 0.0028)

Body to outer rotor axial clearance 0.030 - 0.090 (0.0012 - 0.0035)

CL
Inner rotor to brazed portion of housing clearance 0.045 - 0.091 (0.0018 - 0.0036)

REGULATOR VALVE INSPECTION NJLC0012 MT

Unit: mm (in)

Regulator valve to front cover clearance 0.040 - 0.097 (0.0016 - 0.0038)

AT
OIL CAPACITY NJLC0036
Unit:  (Imp qt)
AX
With oil filter change 2.7 (2-3/8)
Drain and refill
Without oil filter change 2.5 (2-1/4)
SU
Dry engine (engine overhaul) 3.1 (2-3/4)

BR

ST

RS

BT

HA

SC

EL

IDX

LC-9
 ENGINE COOLING SYSTEM
Precautions

Precautions
LIQUID GASKET APPLICATION PROCEDURE NJLC0014
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
I For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
I For areas except oil pan, be sure liquid gasket diameter is 2.0
SEM164F
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.

AEM080

Preparation
SPECIAL SERVICE TOOLS NJLC0015

Tool number
Description
Tool name

WS39930000 Pressing the tube of liquid gasket

Tube presser

NT052

EG17650301 Adapting radiator cap tester to radiator filler neck

Radiator cap tester a: 28 (1.10) dia.
adapter b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

NT564

KV99103510 Installing radiator upper and lower tanks

Radiator plate pliers A

NT224

KV99103520 Removing radiator upper and lower tanks

Radiator plate pliers B

NT225

LC-10
ENGINE COOLING SYSTEM
Cooling Circuit

Cooling Circuit NJLC0016

GI

MA

EM

EC

FE

CL

MT

AT

SLC564B
AX

SU

BR

System Check NJLC0017 ST

WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure fluid escaping from the RS
radiator.
Wrap a thick cloth around the cap. Slowly turn it a quarter turn
to allow built-up pressure to escape. Carefully remove the cap BT
by turning it all the way.
CHECKING COOLING SYSTEM HOSES NJLC0017S01 HA
Check hoses for the following:
I Improper attachment
I Leaks SC
I Cracks
I Damage
EL
I Loose connections
I Chafing
I Deterioration IDX

LC-11
 ENGINE COOLING SYSTEM
System Check (Cont’d)
CHECKING RADIATOR NJLC0017S04
Check radiator for mud or clogging. If necessary, clean radiator as
follows.
I Be careful not to bend or damage the radiator fins.
I When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, rediator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1. Apply water by hose to the back side of the radiator core ver-
tically download.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor.
4. Blow air into the back side of radiator core vertically download.
I Use compressesd air lower than 490 kPa (4.9 bar, 5 kg/cm2,
71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.

CHECKING RADIATOR CAP NJLC0017S03

To check radiator cap, apply pressure to radiator cap with radiator
cap tester (commercial service tool) and radiator cap tester adapter
(SST).
Radiator cap relief pressure:
Standard
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit
59 kPa (0.59 bar, 0.6 kg/cm2, 9 psi)
SLC613-A

Pull the negative pressure valve to open it.

Check that it closes completely when released.
I Check the radiator cap negative pressure valve for contamina-
tion or damage to the valve seat.
I Move the negative pressure valve to check for abnormalities to
the opening/shutting operation.
CAUTION:
I Be sure to perform the inspections after cooling down the
engine.
I Before connecting the radiator cap to the radiator cap
SMA967B tester adapter (SST), apply engine coolant to the cap seal-
ing.
I Replace the radiator cap if any non-standard conditions are
found with the negative pressure valve, or if the valve opening
pressure is out of the standard range.

LC-12
 ENGINE COOLING SYSTEM
System Check (Cont’d)
CHECKING COOLING SYSTEM FOR LEAKS NJLC0017S02
To check for leakage, apply pressure to the cooling system with
radiator cap tester (commercial service tool) and radiator cap tester GI
adapter (SST).
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
MA
CAUTION:
I Higher pressure than specified may cause radiator dam- EM
age.
I Be sure to perform the inspections after cooling down the
SLC756AA engine.
I Use a hose adapter between the cap tester and filler neck
to prevent the radiator filler neck from deforming.
I If any non-standard conditions are found, repair or replace the EC
malfunctioning parts.
FE

CL

MT
Water Pump
REMOVAL AND INSTALLATION AT
NJLC0018

AX

SU

BR

ST

RS

BT

SLC570B
HA

1. Gasket 3. Water pump pulley 4. Front cover SC

2. Water pump

EL

IDX

LC-13
 ENGINE COOLING SYSTEM
Water Pump (Cont’d)
CAUTION:
I When removing water pump assembly, be careful not to
get engine coolant on drive belt.
I Water pump cannot be disassembled and should be
replaced as a unit.
1. Drain engine coolant.
Refer to LC-18, “Changing Engine Coolant”.
2. Remove front right wheel.
3. Remove front right undercover and front right fender protector.
4. Remove drive belts and idler pulley. Refer to EM-17, “DRIVE
SEM859F BELTS”.
5. Loosen water pump pulley bolts.
6. Remove water pump pulley.
7. Remove water pump bolts.
8. Remove water pump.
9. Reinstall parts in the reverse order of removal.

INSPECTION NJLC0019
I Check body assembly and vane for rust or corrosion.
I Check for rough operation due to excessive end play.
I After installing water pump, and check for leaks using radiator
cap tester (commercial service tool) and radiator cap tester
adapter (SST: EG17650301).

SEM860F

LC-14
 ENGINE COOLING SYSTEM
Thermostat

Thermostat
REMOVAL AND INSTALLATION NJLC0021
GI

MA

EM

EC

FE

CL

MT

AT

AX
SLC565B
SU
1. Gasket 5. Air relief plug 9. Water inlet
2. Thermostat housing 6. Thermostat 10. Bracket
3. Radiator upper hose 7. Gum ring 11. Heater hose BR
4. Washer 8. Radiator lower hose 12. Water hose

ST
Be careful not to spill engine coolant over engine compart-
ment. Use a rag to absorb engine coolant.
1. Drain engine coolant. RS
Refer to LC-18, “Changing Engine Coolant”.
2. Remove water inlet, then take out thermostat.
BT

HA

3. Install gum ring to thermostat. SC

EL

IDX

SEM862F

LC-15
 ENGINE COOLING SYSTEM
Thermostat (Cont’d)
4. Install thermostat with jiggle valve or air bleeder at upper side.
After installation, run engine for a few minutes, and check
for leaks.

SEM863F

INSPECTION NJLC0022
1. Check for valve seating condition at normal room temperature.
It should seat tightly.
2. Check valve opening temperature and valve lift.
Valve opening temperature °C (°F) 80.5 - 83.5 (177 - 182)

Valve lift mm/°C (in/°F) More than 8/95 (0.31/203)

Valve closing temperature °C (°F) 77 (171)

SLC343

LC-16
 ENGINE COOLING SYSTEM
Radiator

Radiator
COMPONENTS =NJLC0025
GI

MA

EM

EC

FE

CL

MT

AT

AX
SLC566B
SU
1. Reservoir tank cap 6. Mounting bracket 11. Radiator lower hose
2. Reservoir tank 7. Mounting rubber 12. A/T fluid cooler hose (A/T models)
3. Reservoir tank bracket 8. Radiator 13. Radiator upper hose BR
4. Reservoir hose 9. O-ring 14. Cooling fan assembly
5. Radiator cap 10. Radiator drain plug
ST
WARNING:
Never remove the radiator cap when the engine is hot. Serious RS
burns could occur from high pressure engine coolant escap-
ing from the radiator.
BT

HA

SC

EL

IDX

LC-17
 ENGINE COOLING SYSTEM
Cooling Fan

Cooling Fan NJLC0026

COMPONENTS NJLC0026S01

SLC567B

1. Fan motor 3. Cooling fan (RH) 4. Cooling fan (LH)

2. Fan shroud

CONTROL SYSTEM NJLC0026S02

Cooling fans are controlled by the ECM. For details, refer to
EC-139 or EC-433, “DTC P1217 ENGINE OVER
TEMPERATURE”.

Changing Engine Coolant NJLC0037

WARNING:
To avoid the danger of being scalded, never change the engine
coolant when the engine is hot.
Wrap a thick cloth around cap and carefully remove the cap.
First turn the cap a quarter of a turn to release built-up pres-
sure. Then turn the cap all the way.
— DRAINING ENGINE COOLANT — NJLC0037S01
1. Set air conditioning system as follows to prevent engine cool-
ant from remaining in the system.
SLC276BC

LC-18
 ENGINE COOLING SYSTEM
Changing Engine Coolant (Cont’d)
a. Turn ignition switch ON and set temperature controller to maxi-
mum hot position.
b. Wait 10 seconds before turning ignition switch OFF. GI

MA

EM

2. Open radiator drain plug at the bottom of radiator, then remove

radiator filler cap to drain engine coolant.
3. Remove reservoir tank, drain engine coolant, then clean res-
EC
ervoir tank.
I Be careful not to allow engine coolant to contact drive FE
belts.
4. Cover the exhaust tube heat insulator to prevent from splash-
ing engine coolant. CL

SMA033D
MT
5. Remove drain plug on cylinder block and air relief plug.
6. Check drained engine coolant for contaminants such as rust, AT
corrosion or discoloration. If contaminated flush engine cooling
system, refer to LC-20, “FLUSHING COOLING SYSTEM”.
7. Blow the engine coolant around the exhaust tube heat insula- AX
tor.
SU

BR
SLC277BA

ST

RS

BT

HA
SLC568B

— REFILLING ENGINE COOLANT — NJLC0037S02

SC
1. Install reservoir tank, radiator drain plug and cylinder block
drain plug.
I Apply sealant to the thread of cylinder block drain plug. EL
: 34.3 - 44.1 N·m (3.5 - 4.4 kg-m, 26 - 32 ft-lb)
2. Fill radiator slowly with engine coolant until engine coolant IDX
spills from the air relief plug, then install air relief plug.
Air relief plug:
: 6.7 - 7.9 N·m (0.68 - 0.80 kg-m, 59 - 69 in-lb)
I Use genuine NISSAN anti-freeze coolant or equivalent
mixed with water (distilled or demineralized).
LC-19
 ENGINE COOLING SYSTEM
Changing Engine Coolant (Cont’d)
Refer to MA-8, “RECOMMENDED FLUIDS AND LUBRICANTS”.
Engine coolant capacity (With reservoir tank):
Unit:  (Imp qt)

M/T 6.7 (5-7/8)

A/T 6.6 (5-7/8)

Reservoir tank engine coolant capacity:

0.7  (5/8 Imp qt)
I Pour engine coolant through engine coolant filler neck
SMA182B slowly to allow air in system to escape.
3. Fill radiator and reservoir tank to the specified level.
4. Warm up engine to normal operating temperature without
radiator cap installed.
I If engine coolant overflows radiator filler hole, install filler
cap.
5. Run engine at 2,500 rpm for 10 seconds and return to idle
speed with radiator cap installed.
I Repeat two or three times.
Watch engine coolant temperature gauge so as not to over-
heat the engine.
SMA412B 6. Stop engine and cool it down.
I Cool down using a fan to reduce the time.
I 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 4 through 7 two or more times with radiator cap
installed until engine coolant level no longer drops.
9. Check cooling system for leaks with engine running.
10. 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 positions between COOL
and HOT.
I Sound may be noticeable at heater water cock.
11. If sound is heard, bleed air from cooling system by repeating
steps 4 through 7 until engine coolant level no longer drops
I Clean excess engine coolant from engine.
— FLUSHING COOLING SYSTEM — NJLC0037S03
1. Open air relief plug.
2. Fill radiator with water until water spills from the air relief hole,
then close air relief plug. Fill radiator and reservoir tank with
water and reinstall radiator cap.
3. Run engine and warm it up to normal operating temperature.
4. Rev engine two or three times under no-load.
5. Stop engine and wait until it cools down.
6. Drain water.
7. Repeat steps 1 through 6 until clear water begins to drain from
radiator.

LC-20
 ENGINE COOLING SYSTEM
Radiator (Aluminum type)

Radiator (Aluminum type) NJLC0081

PREPARATION NJLC0081S01
GI

MA

EM

EC

FE

CL

SLC569B
MT
1. Upper tank 4. Lower tank 7. O-ring
2. Sealing rubber 5. Conical washer 8. Oil cooler AT
3. Core 6. Washer

AX

SU

BR
1. Attach the spacer to the tip of radiator plate pliers A (SST).
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in) ST
wide x 8.5 mm (0.335 in) long.
2. Make sure that when radiator plate pliers A (SST) are closed
dimension H′′ is approx. 7.6 mm (0.299 in).
RS
3. Adjust dimension H′′ with the spacer, if necessary.
BT

HA
SLC655C

DISASSEMBLY NJLC0081S02
SC
1. Remove upper or lower tanks with radiator plate pliers B
(SST).
EL

IDX

SLC903

LC-21
 ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont’d)
I Grip the crimped edge and bend it upwards so that radiator
plate pliers B (SST: KV99103520) slips off.
Do not bend excessively.

SLC893

I In areas where radiator plate pliers B (SST: KV99103520) can-

not be used, use a screwdriver to bend the edge up.
Be careful not to damage tank.
2. Remove sealing rubbers.

SLC930

3. Make sure the edge stands straight up.

4. Remove oil cooler from tank. (A/T model only)

SLC931

ASSEMBLY NJLC0081S03
1. Install oil cooler. (A/T model only)
Pay attention to direction of conical washer.

SBIA0419E

2. Clean contact portion of tank.

SLC932

LC-22
 ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont’d)
3. Install sealing rubber.
Push it in with fingers.
Be careful not to twist sealing rubber. GI

MA

EM

SLC917A

4. Caulk tank in specified sequence with radiator plate pliers A

(SST).
EC

FE

CL

SLC904
MT

AT

AX

SU

SLC896
BR
I Use pliers in the locations where plate pliers A (SST:
KV99103510) cannot be used. ST

RS

BT

HA
SLC897

5. Make sure that the rim is completely crimped down. SC

Standard height “H”:
8.0 - 8.4 mm (0.315 - 0.331 in)
6. Confirm that there is no leakage. EL
Refer to LC-24, “INSPECTON”.
IDX

SLC554A

LC-23
 ENGINE COOLING SYSTEM
Radiator (Aluminum type) (Cont’d)
INSPECTION NJLC0081S04
1. Apply pressure with radiator cap tester (commercial service
tool) and radiator cap tester adapter (SST).
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler to seal its inlet and outlet. (A/T
model only)
SLC933

2. Check for leakage by soaking radiator in water container with

the testing pressure applied.

SLC934

LC-24
 ENGINE COOLING SYSTEM
Overheating Cause Analysis

Overheating Cause Analysis NJLC0028

Symptom Check items GI

Water pump malfunction Worn or loose drive belt

Thermostat stuck closed — MA

Dust contamination or
Poor heat transfer paper clogging —
Damaged fins EM
Mechanical damage

Clogged radiator cooling Excess foreign material

tube (rust, dirt, sand, etc.)

Cooling fan does not oper-

ate EC
Reduced air flow High resistance to fan rota- Fan assembly —
tion FE
Damaged fan blades

Damaged radiator shroud — — — CL

Improper engine coolant
— — —
Cooling sys- mixture ratio
tem parts MT
malfunction Poor engine coolant quality — Engine coolant viscosity —

Loose clamp
Cooling hose AT
Cracked hose

Water pump Poor sealing

AX
Loose
Radiator cap
Engine coolant leaks
Poor sealing SU
O-ring for damage, deterio-
Insufficient coolant ration or improper fitting
Radiator BR
Cracked radiator tank

Cracked radiator core

ST
Reservoir tank Cracked reservoir tank

Cylinder head deterioration

Exhaust gas leaks into RS
Overflowing reservoir tank Cylinder head gasket dete-
cooling system
rioration
BT

HA

SC

EL

IDX

LC-25
 ENGINE COOLING SYSTEM
Overheating Cause Analysis (Cont’d)

Symptom Check items

High engine rpm under no

load

Driving in low gear for

Abusive driving
extended time

Driving at extremely high

speed
— Overload on engine
Powertrain system malfunc-
tion

Installed improper size

Except cool- wheels and tires —
ing system
parts mal- Dragging brakes
function
Improper ignition timing

Blocked bumper —

Installed car brassiere

Blocked radiator grille Mud contamination or
Blocked or restricted air paper clogging —
flow
Blocked radiator —

Blocked condenser
Blocked air flow
Installed large fog lamp

Service Data and Specifications (SDS)

THERMOSTAT NJLC0029

Valve opening temperature °C (°F) 80.5 - 83.5 (177 - 182)

Valve lift mm/°C (in/°F) More than 8/95 (0.31/203)

Valve closing temperature °C (°F) 77 (171)

RADIATOR NJLC0030
Unit: kPa (bar, kg/cm2, psi)

Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14)

Cap reliefpressure
Limit 59 (0.59, 0.6, 9)

Leakage test pressure 157 (1.57, 1.6, 23)

COOLANT CAPACITY NJLC0038

Unit:  (Imp qt)

M/T* 6.7 (5-7/8)

A/T* 6.6 (5-7/8)

Reservoir tank 0.7 (5/8)

*: With reservoir tank

LC-26