Engine Cooling System (Vq): Removal & Installation Nissan Frontier D40

Block Plug and Block Heater Installation

TIGHTENING TORQUE SPECIFICATIONS

Scheme 46

Scheme 47

1. 2. 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.
2. 3. Remove the vented reservoir cap and replace it with a non-vented reservoir cap before filling the cooling system.
3. 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)
4. 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) ". Cooling system capacity (with reservoir): Refer to " «FLUIDS AND LUBRICANTS»(ref-272345-S09354654722007111800000) ".
5. 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) CAUTION: The compressed air supply must be equipped with an air dryer. see scheme 13: Attaching Gauge Body Assembly
6. 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.
7. 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
8. 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. see scheme 14: Checking Vacuum Gauge Reading
9. 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.
10. 11. Remove the Tool from the radiator neck opening and install the radiator cap.
11. 12. Remove the reservoir cap.
12. 13. Fill the cooling system reservoir tank to the specified level. Run the engine to warm up the cooling system and top up the system as necessary before installing the reservoir cap.

INSTALLATION

Installation is in the reverse order of removal.

REMOVAL

1. Remove air duct. Refer to " «REMOVAL AND INSTALLATION»(ref-272352-S25129190762007111800000) ".
2. Remove the engine front undercover.
3. Remove the upper and lower radiator shrouds. Refer to " «REMOVAL AND INSTALLATION»(ref-272353-S10513331412007111800000) ".
4. Remove drive belts. Refer to " «REMOVAL AND INSTALLATION»(ref-272352-S20981100952007111800000) ".
5. Remove cooling fan.

Installation is in the reverse order of removal.

1. Install cooling fan with its front mark "F" facing front of engine. Refer to " «REMOVAL AND INSTALLATION (CRANKSHAFT DRIVEN TYPE)»(ref-272353-S41233293722007111800000) ".

Installation is in the reverse order of removal.

1. Cooling fan is controlled by ECM. For details, refer to " «COOLING FAN CONTROL»(ref-272339-S05349899892007111800000) ".

Identifying Water Pump Components With Torque Specifications. Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

1. Remove undercover with power tool.
2. Remove drive belts. Refer to " «REMOVAL AND INSTALLATION»(ref-272352-S20981100952007111800000) ".
3. Drain engine coolant. Refer to " «ENGINE COOLANT»(ref-272353-S35078751652007111800000) ". CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
4. Remove radiator hoses (upper and lower) and cooling fan assembly. Refer to " «ENGINE COOLING FAN»(ref-272353-S32715010432007111800000) ".
5. Remove chain tensioner cover and water pump cover from front timing chain case, using Tool. Tool number: V10111100 (J-37228) see scheme 25: Identifying Chain Tensioner Cover
6. Remove timing chain tensioner (primary) as follows: Loosen clip of timing chain tensioner (primary), and release plunger stopper. (1) Insert plunger into tensioner body by pressing slack guide. (2) Keep slack guide pressed and hold plunger in by pushing stopper pin through the tensioner body hole and plunger groove. (3) see scheme 26: Inserting Plunger Into Tensioner Body Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose. see scheme 27: Turning Crankshaft Pulley Remove bolts and remove timing chain tensioner (primary). CAUTION: Be careful not to drop bolts inside timing chain case. see scheme 28: Identifying Bolts And Timing Chain Tensioner (Primary)
7. Remove water pump as follows: Remove three water pump bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley counterclockwise until timing chain looseness on water pump sprocket becomes maximum. (Scheme 49): Identifying Water Pump Screw M8 bolts [pitch: 1.25 mm (0.049 in) length: approx. 50 mm (1.97 in)] into water pumps upper and lower bolt holes until they reach timing chain case. Then, alternately tighten each bolt for a half turn, and pull out water pump. CAUTION: Pull straight out while preventing vane from contacting socket in installation area. Remove water pump without causing sprocket to contact timing chain. Remove M8 bolts and O-rings from water pump. CAUTION: Do not disassemble water pump. NOTE: Do not reuse O-rings. (Scheme 50): Identifying M8 Bolts

Scheme 55

1. Check for badly rusted or corroded water pump body assembly.
2. Check for rough operation due to excessive end play.
3. Replace water pump, if necessary. (Scheme 51): Checking End Play

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

1. Install new O-rings to water pump. NOTE: Apply engine oil to O-rings. Locate O-ring with white paint mark to engine front side. (Scheme 52): Identifying O-Rings To Water Pump
2. Install water pump. CAUTION: Do not allow timing chain case to nip O-rings when install water pump. Make sure that timing chain and water pump sprocket are engaged. Insert water pump by tightening bolts alternately and evenly.
3. Install timing chain tensioner (primary) as follows: (Scheme 53): Identifying Timing Chain And Water Pump Sprocket Remove dust and foreign material completely from backside of timing chain tensioner (primary) and from installation area of rear timing chain case. Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose. Install timing chain tensioner (primary) with its stopper pin attached. CAUTION: Be careful not to drop bolts inside timing chain case. Remove stopper pin. (Scheme 54): Identifying Timing Chain Tensioner (Primary) With Stopper Pin Make sure again that timing chain and water pump sprocket are engaged.
4. Install chain tensioner cover and water pump cover as follows: Before installing, remove all traces of old liquid gasket from mating surface of water pump cover and chain tensioner cover using scraper. Also remove traces of old liquid gasket from the mating surface of front timing chain case. (Scheme 55): Identifying Chain Tensioner Cover And Water Pump Cover Apply a continuous bead of liquid gasket, to mating surface of chain tensioner and water pump cover, using Tool. Tool number: WS39930000 ( - ) Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-272334-S29650495302007111800000) ". CAUTION: Attaching should be done within 5 minutes after coating. Tighten bolts to specified torque. Refer to " «REMOVAL AND INSTALLATION»(ref-272353-S10129699462007111800000) ". (Scheme 56): Applying Continuous Bead Of Liquid Gasket
5. Refill engine coolant system. Refer to " «REFILLING ENGINE COOLANT»(ref-272353-S34574241602007111800000) ". Apply liquid gasket to the thread of water drain plug (front). Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-272334-S29650495302007111800000) ".
6. Installation of the remaining components is in the reverse order of removal after this step. After starting engine, let idle for three minutes, then rev engine up to 3,000 rpm under no load to purge air from the high-pressure chamber of chain tensioner. Engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.

Installation is in the reverse order of removal, paying attention to the following.

1. Be careful not to spill engine coolant over engine room. Use rag to absorb engine coolant.

1. Completely drain engine coolant. Refer to " «DRAINING ENGINE COOLANT»(ref-272353-S18152922612007111800000) ". CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
2. Remove A/T fluid charging pipe Refer to " «TRANSMISSION ASSEMBLY»(ref-272346-S07180306192007111800000) ".
3. Remove the rocker cover (right bank). Refer to " «REMOVAL AND INSTALLATION»(ref-272352-S09281615442007111800000) ".
4. Remove engine coolant temperature sensor as necessary. CAUTION: Be careful not to damage engine coolant temperature sensor.
5. Remove water outlet, heater pipe, water bypass hoses and water pipe.

Installation is in the reverse order of removal, paying attention to the following.

1. Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.
2. When inserting water pipe into water outlet, apply neutral detergent to O-ring.