Engine Cooling System (Qr): Other Nissan Frontier D40

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SUPPLEMENTAL RESTRAINT SYSTEM and SEAT BELTS articles.

Scheme 18

1. After removing nuts and bolts, separate the mating surface, using Tool and remove old liquid gasket sealing. Tool number: KV10111100 (J-37228) CAUTION: Be careful not to damage the mating surfaces.
2. Tap Tool to insert it, and then slide it by tapping on the side as shown.
3. In areas where Tool is difficult to use, use plastic hammer to lightly tap the parts, to remove it. CAUTION: If for some unavoidable reason suitable tool such as screwdriver is used, be careful not to damage the mating surfaces. (Scheme 18): Identifying Tool

Scheme 19

Scheme 20

Scheme 21

1. Remove old liquid gasket adhering to the liquid gasket application surface and the mating surface, Using scraper. Remove liquid gasket completely from the groove of the liquid gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering moisture, grease and foreign materials. (Scheme 19): Identifying Scraper
3. Attach liquid gasket tube to Tool. Tool number: WS39930000 ( - ) Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-272334-S29650495302007111800000) ".
4. Apply liquid gasket without breaks to the specified location with the specified dimensions. If there is a groove for the liquid gasket application, apply liquid gasket to the groove. (Scheme 20): Applying Genuine RTV Silicone Sealant As for the bolt holes, normally apply liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of service manual. Within five minutes of liquid gasket application, install the mating component. If liquid gasket protrudes, wipe it off immediately. Do not retighten nuts or bolts after the installation. After 30 minutes or more have passed from the installation, fill engine oil and engine coolant. (Scheme 21): Applying Bead Of Sealant To Bolt Holes CAUTION: If there are specific instructions in this manual, observe them.

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

SPECIAL SERVICE TOOLS REFERENCE Tool number (Kent-Moore No.) Tool name Description EG17650301 (J-33984-A) Radiator cap tester adapter Adapting 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) KV10111100 (J-37228) Seal cutter Removing chain tensioner cover and water pump cover WS39930000 ( - ) Tube presser Pressing the tube of liquid gasket - (J-23688) Engine coolant refractometer Checking concentration of ethylene glycol in engine coolant

Scheme 22

Scheme 23

Commercial Service Tools

COMMERCIAL SERVICE TOOLS REFERENCE Tool name Description Power tool Loosening nuts and bolts Radiator cap tester Checking radiator and radiator cap

Scheme 24

System Check

CHECKING COOLING SYSTEM HOSES

Check hoses for the following

1. Improper attachment
2. Leaks
3. Cracks
4. Damage
5. Loose connections
6. Chafing
7. Deterioration

Scheme 25

1. Check if the reservoir tank coolant level is within MIN to MAX when the engine is cool.
2. Adjust engine coolant level as necessary. (Scheme 24): Checking Coolant Level

CHECKING COOLING SYSTEM FOR LEAKS

To check for leakage, apply pressure to the cooling system using Tool.

Tool number: EG17650301 (J-33984-A)

Testing pressure: 137 kPa (1.4 kg/cm 2 , 20 psi)

Applying Pressure To Cooling System Using Tool. Scheme 26

Scheme 27

Scheme 28

1. Inspect the reservoir cap. Replace the cap if the metal plunger cannot be seen around the edge of the black rubber gasket. Replace the cap if deposits of waxy residue or other foreign material are on the black rubber gasket or the metal retainer. NOTE: Thoroughly wipe out the reservoir filler neck to remove any waxy residue or foreign material.
2. Pull the negative-pressure valve to open it and check that it closes completely when released. Check that there is no dirt or damage on the valve seat of the reservoir cap negative-pressure valve. Check that there are no abnormalities in the opening and closing conditions of the negative-pressure valve. see scheme 9: Checking Radiator Cap
3. Check reservoir cap relief pressure using Tool. Tool number: EG17650301 (J-33984-A) Standard: 98-118 kPa (0.99-1.20 kg/cm 2, 14-17 psi) When connecting the reservoir cap to the tester, apply water or coolant to the cap seal surface. Replace the reservoir cap if there is an abnormality in the negative-pressure valve, or if the open-valve pressure is outside of the standard values. (Scheme 25): Checking Radiator Cap Relief Pressure

CHECKING RADIATOR

Check radiator for mud or clogging. If necessary, clean radiator as follows.

1. Apply water by hose to the back side of the radiator core, with the hose pointed vertically downward.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core, with the air hose pointed vertically downward. Use compressed air lower than 490 kPa (5 kg/cm 2 , 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.
6. Check for leaks.

Changing Engine Coolant

Scheme 29

Scheme 30

1. Remove the engine undercover using power tool.
2. Open the radiator drain plug at the bottom of the radiator, and remove the radiator filler cap. This is the only step required when partially draining the cooling system (radiator only). Do not to allow the coolant to contact the drive belts. see scheme 11: Identifying Radiator Drain Plug
3. Follow this step for heater core removal/replacement only. Disconnect the upper heater hose at the engine side and apply moderate air pressure [103.46 kPa (15 psi, 1.055 kg/cm 2 ) maximum air pressure] into the hose for 30 seconds to blow the excess coolant out of the heater core.
4. When draining all of the coolant in the system, remove the reservoir tank and drain the coolant, then clean the reservoir tank before installation.
5. When draining all of the coolant in the system for engine removal or repair, open the drain plug on the cylinder block. (Scheme 27): Opening Drain Plug On Cylinder Block
6. Check the drained coolant for contaminants such as rust, corrosion or discoloration. If the coolant is contaminated, flush the engine cooling system. Refer to " «FLUSHING COOLING SYSTEM»(ref-272341-S22561573812007111800000) ".

Scheme 31

Scheme 32

1. Install the radiator drain plug. Install the reservoir tank and cylinder block drain plug, if removed for a total system drain or for engine removal or repair. The radiator must be completely empty of coolant and water. Apply sealant to the threads of the cylinder block drain plugs. Use Genuine High Performance Thread Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-272334-S29650495302007111800000) ". Radiator drain plug: Refer to " «RADIATOR»(ref-272341-S00430165932007111800000) ". Cylinder block drain plug: Refer to " «CYLINDER BLOCK»(ref-272340-S24105436542007111800000) ".
2. If disconnected, reattach the upper radiator hose at the engine side.
3. Set the vehicle heater controls to the full HOT and heater ON position. Turn the vehicle ignition ON with the engine OFF as necessary to activate the heater mode.
4. Install the Tool by installing the radiator cap adapter onto the radiator neck opening. Then attach the gauge body assembly with the refill tube and the venturi assembly to the radiator cap adapter. Tool number: KV991J0070 (J-45695)
5. Insert the refill hose into the coolant mixture container that is placed at floor level. Make sure the ball valve is in the closed position. Use Genuine NISSAN Long Life Anti-freeze coolant or equivalent, mixed 50/50 with distilled water or demineralized water. Refer to " «ANTI-FREEZE COOLANT MIXTURE RATIO»(ref-272345-S40481991532007111800000) ". Engine coolant capacity (with reservoir tank): Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S09354654722007111800000) ".
6. Install an air hose to the venturi assembly, the air pressure must be within specification. Compressed air supply pressure: 5.7-8.5 kPa (5.6-8.4 kg/cm 2, 80-120 psi) (Scheme 28): Attaching Gauge Body Assembly CAUTION: The compressed air supply must be equipped with an air dryer.
7. The vacuum gauge will begin to rise and there will be an audible hissing noise. During this process open the ball valve on the refill hose slightly. Coolant will be visible rising in the refill hose. Once the refill hose is full of coolant, close the ball valve. This will purge any air trapped in the refill hose.
8. Continue to draw the vacuum until the gauge reaches 28 inches of vacuum. The gauge may not reach 28 inches in high altitude locations, refer to the vacuum specifications based on the altitude above sea level. Altitude above sea level Vacuum gauge reading 0-100 m (328 ft): 28 inches of vacuum 300 m (984 ft): 27 inches of vacuum 500 m (1,641 ft): 26 inches of vacuum 1,000 m (3,281 ft): 24-25 inches of vacuum (Scheme 29): Checking Vacuum Gauge Reading
9. When the vacuum gauge has reached the specified amount, disconnect the air hose and wait 20 seconds to see if the system loses any vacuum. If the vacuum level drops, perform any necessary repairs to the system and repeat steps 6 - 8 to bring the vacuum to the specified amount. Recheck for any leaks.
10. Place the coolant container (with the refill hose inserted) at the same level as the top of the radiator. Then open the ball valve on the refill hose so the coolant will be drawn up to fill the cooling system. The cooling system is full when the vacuum gauge reads zero. CAUTION: Do not allow the coolant container to get too low when filling, to avoid air from being drawn into the cooling system.
11. Remove the Tool from the radiator neck opening.
12. Fill the cooling system reservoir tank to the specified level and install the radiator cap. Run the engine to warm up the cooling system and top up the system as necessary.

Fan Coupling

Inspect fan coupling for oil leakage and bimetal conditions.

Identifying Thermostat And Thermostat Housing Components With Torque Specifications. Scheme 33

Cooling Fan

Inspect cooling fan for crack or unusual bend.

1. If anything is found, replace cooling fan.

Standard

THERMOSTAT REFERENCE

1. If out of the standard, replace thermostat.

Standard values

STANDARD VALUES REFERENCE CHART

RESERVOIR CAP

RESERVOIR CAP SPECIFICATIONS

THERMOSTAT

THERMOSTAT SPECIFICATIONS