Qashqai J11. Engine cooling system - part 1

 

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Qashqai J11. Engine cooling system - part 1

 

 

CO-1

ENGINE

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SECTION 

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CONTENTS

ENGINE COOLING SYSTEM

HRA2DDT

PRECAUTION ...............................................

4

PRECAUTIONS ...................................................

4

Precaution for Supplemental Restraint System 
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................
..

4

Precautions Necessary for Steering Wheel Rota-
tion After Battery Disconnection  ..............................
..

4

Precautions for Removing Battery Terminal  .............

5

PREPARATION ............................................

7

PREPARATION ...................................................

7

Special Service Tool  .................................................

7

SYSTEM DESCRIPTION  ..............................

8

DESCRIPTION ....................................................

8

Engine Cooling System  .............................................

8

SYMPTOM DIAGNOSIS  ...............................

9

OVERHEATING CAUSE ANALYSIS ..................

9

Troubleshooting Chart ...............................................

9

PERIODIC MAINTENANCE .........................

11

ENGINE COOLANT  ...........................................

11

Inspection ................................................................

11

Draining ...................................................................

11

Refilling ...................................................................

11

Flushing ...................................................................

13

RESERVOIR TANK CAP  ...................................

15

Inspection ................................................................

15

RADIATOR .........................................................

16

Inspection ................................................................

16

REMOVAL AND INSTALLATION ...............

17

RADIATOR ........................................................

17

Exploded View .........................................................

17

Removal and Installation  .........................................

17

Inspection ................................................................

19

COOLING FAN ..................................................

20

Exploded View .........................................................

20

Removal and Installation  .........................................

20

Disassembly and Assembly .....................................

21

Inspection ................................................................

21

WATER PUMP  ..................................................

22

Exploded View .........................................................

22

Removal and Installation  .........................................

22

Inspection ................................................................

23

THERMOSTAT ..................................................

25

Exploded View .........................................................

25

Removal and Installation  .........................................

25

Inspection ................................................................

26

WATER OUTLET  ..............................................

27

Exploded View .........................................................

27

Removal and Installation  .........................................

27

SERVICE DATA AND SPECIFICATIONS 
(SDS) ............................................................

29

SERVICE DATA AND SPECIFICATIONS 
(SDS) .................................................................

29

Periodical Maintenance Specification ......................

29

Radiator ...................................................................

29

Thermostat ..............................................................

29

MR20DD

PRECAUTION ..............................................

30

PRECAUTIONS .................................................

30

Precaution for Supplemental Restraint System 
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................

30

Precautions for Removing Battery Terminal ............

30

CO-2

PREPARATION ...........................................

31

PREPARATION  .................................................

31

Commercial Service Tools ....................................

31

Lubricant or/and Sealant  ........................................

31

SYSTEM DESCRIPTION  ............................

32

DESCRIPTION ...................................................

32

Engine Cooling System  ..........................................

32

Engine Cooling System Schematic  ........................

34

SYMPTOM DIAGNOSIS  .............................

36

OVERHEATING CAUSE ANALYSIS  ................

36

Troubleshooting Chart  ............................................

36

PERIODIC MAINTENANCE ........................

38

ENGINE COOLANT  ...........................................

38

Inspection ...............................................................

38

Draining ..................................................................

38

Refilling ...................................................................

38

Flushing ..................................................................

40

RESERVOIR TANK CAP ...................................

41

Inspection ...............................................................

41

RADIATOR ........................................................

42

Inspection ...............................................................

42

REMOVAL AND INSTALLATION ...............

43

RADIATOR ........................................................

43

Exploded View  ........................................................

43

Removal and Installation  ........................................

43

Inspection ...............................................................

46

COOLING FAN  ..................................................

47

Exploded View  ........................................................

47

Removal and Installation  ........................................

47

Disassembly and Assembly ....................................

48

Inspection ...............................................................

48

WATER PUMP  ...................................................

49

Exploded View  ........................................................

49

Removal and Installation  ........................................

49

Inspection ...............................................................

49

THERMOSTAT ..................................................

51

Exploded View  ........................................................

51

Removal and Installation  ........................................

51

Inspection ...............................................................

52

WATER OUTLET  ...............................................

53

Exploded View  ........................................................

53

Removal and Installation  ........................................

53

Inspection ...............................................................

54

SERVICE DATA AND SPECIFICATIONS 
(SDS) ...........................................................

56

SERVICE DATA AND SPECIFICATIONS 
(SDS) .................................................................

56

Periodical Maintenance Specification  .....................

56

Radiator ..................................................................

56

Thermostat ..............................................................

56

Water Control Valve ................................................

56

K9K

PRECAUTION ............................................

57

PRECAUTIONS  .................................................

57

Precautions for Removing Battery Terminal  ...........

57

Precaution for Supplemental Restraint System 
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................

58

Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect ...................................

58

Precaution for Liquid Gasket ...................................

59

PREPARATION ..........................................

61

PREPARATION .................................................

61

Special Service Tool  ...............................................

61

SYSTEM DESCRIPTION  ...........................

62

DESCRIPTION ...................................................

62

Cooling Circuit .........................................................

62

SYMPTOM DIAGNOSIS  ............................

63

OVERHEATING CAUSE ANALYSIS  ................

63

Troubleshooting Chart  ............................................

63

PERIODIC MAINTENANCE  .......................

65

ENGINE COOLANT ...........................................

65

Inspection ................................................................

65

Draining ...................................................................

65

Refilling ...................................................................

65

Flushing ..................................................................

67

RESERVOIR TANK CAP  ..................................

68

Inspection ................................................................

68

RADIATOR ........................................................

69

Inspection ................................................................

69

REMOVAL AND INSTALLATION ..............

70

RADIATOR ........................................................

70

Exploded View  ........................................................

70

Removal and Installation .........................................

70

Inspection ................................................................

72

COOLING FAN  ..................................................

73

Exploded View  ........................................................

73

Removal and Installation .........................................

73

Disassembly and Assembly  ....................................

74

Inspection ................................................................

74

WATER PUMP ...................................................

75

CO-3

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Exploded View  ........................................................

75

Removal and Installation .........................................

75

Inspection ................................................................

75

THERMO PLUNGER UNIT  ................................

77

Exploded View  ........................................................

77

Removal and Installation .........................................

77

THERMOSTAT ...................................................

79

Inspection ................................................................

79

WATER OUTLET  ...............................................

80

Exploded View  ........................................................

80

Removal and Installation .........................................

80

SERVICE DATA AND SPECIFICATIONS 
(SDS) ............................................................

81

SERVICE DATA AND SPECIFICATIONS 
(SDS) ..................................................................

81

Periodical Maintenance Specification  .....................

81

Radiator ...................................................................

81

Thermostat ..............................................................

81

R9M

PRECAUTION ..............................................

82

PRECAUTIONS ..................................................

82

Precautions for Removing Battery Terminal  ...........

82

Precaution for Supplemental Restraint System 
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................

83

PREPARATION ...........................................

84

PREPARATION ..................................................

84

Special Service Tool  ...............................................

84

SYSTEM DESCRIPTION  .............................

85

DESCRIPTION ...................................................

85

Engine Cooling System  ...........................................

85

SYMPTOM DIAGNOSIS  ..............................

87

OVERHEATING CAUSE ANALYSIS .................

87

Troubleshooting Chart .............................................

87

PERIODIC MAINTENANCE .........................

89

ENGINE COOLANT  ..........................................

89

Inspection ................................................................

89

Draining ...................................................................

89

Refilling ....................................................................

89

Flushing ...................................................................

91

RESERVOIR TANK CAP  ..................................

93

Inspection ................................................................

93

RADIATOR ........................................................

94

Inspection ................................................................

94

REMOVAL AND INSTALLATION  ...............

95

RADIATOR ........................................................

95

Exploded View .........................................................

95

Removal and Installation  .........................................

95

Inspection ................................................................

97

COOLING FAN ..................................................

98

Exploded View .........................................................

98

Removal and Installation  .........................................

98

Disassembly and Assembly .....................................

99

Inspection ................................................................

99

WATER PUMP  ................................................

100

Exploded View .......................................................

100

Removal and Installation  .......................................

100

Inspection ..............................................................

101

THERMO PLUNGER UNIT  .............................

102

Exploded View .......................................................

102

Removal and Installation  .......................................

102

WATER OUTLET  ............................................

104

Exploded View .......................................................

104

Removal and Installation  .......................................

104

Inspection ..............................................................

105

SERVICE DATA AND SPECIFICATIONS 
(SDS) ..........................................................

106

SERVICE DATA AND SPECIFICATIONS 
(SDS) ...............................................................

106

Periodical Maintenance Specification ....................

106

Radiator .................................................................

106

Thermostat ............................................................

106

CO-4

< PRECAUTION >

[HRA2DDT]

PRECAUTIONS

PRECAUTION

PRECAUTIONS

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

INFOID:0000000010416335

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. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.

The vehicle may be equipped with a passenger air bag deactivation switch. Because no rear seat exists where
a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a
rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the
instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is
enabled and could inflate for certain types of collision. When the switch is turned to the OFF position, the pas-
senger air bag is disabled and will not inflate. A passenger air bag OFF indicator on the instrument panel lights
up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected
by the passenger air bag deactivation switch.

WARNING:

Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in

the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.

• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal

injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIR BAG”.

• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this

Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.

• The vehicle may be equipped with a passenger air bag deactivation switch which can be operated by

the customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and
will not inflate. When the passenger air bag is switched ON, the passenger air bag is enabled and
could inflate for certain types of collision. After SRS maintenance or repair, make sure the passenger
air bag deactivation switch is in the same position (ON or OFF) as when the vehicle arrived for ser-
vice.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the

ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.

• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the

battery, and wait at least 3 minutes before performing any service.

Precautions Necessary for Steering Wheel Rotation After Battery Disconnection

INFOID:0000000010416336

CAUTION:

Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,

then disconnect both battery cables.

• After finishing work, confirm that all control unit connectors are connected properly, then re-connect

both battery cables.

• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing

work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.

PRECAUTIONS

CO-5

< PRECAUTION >

[HRA2DDT]

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For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.

OPERATION PROCEDURE

1.

Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.

2.

Turn the ignition switch to ACC position.
(At this time, the steering lock will be released.)

3.

Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.

4.

Perform the necessary repair operation.

5.

When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)

6.

Perform self-diagnosis check of all control units using CONSULT.

Precautions for Removing Battery Terminal

INFOID:0000000010508564

• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key

or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.

• When disconnecting the 12V battery terminal, turn off the ACC

power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.

•  For vehicles with the 2-batteries, be sure to connect the main bat-

tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.

•  After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.

NOTE:
The removal of 12V battery may cause a DTC detection error.

HOW TO DISCONNECT 12V BATTERY TERMINAL

Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.

INSTRUCTION 1

1.

Open the hood.

2.

Turn key switch to the OFF position with the driver side door opened.

3.

Get out of the vehicle and close the driver side door.

4.

Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.

CAUTION:

SEF289H

D4D engine

: 20 minutes

HRA2DDT

: 12 minutes

K9K engine

: 4 minutes

M9R engine

: 4 minutes

R9M engine

: 4 minutes

V9X engine

: 4 minutes

CO-6

< PRECAUTION >

[HRA2DDT]

PRECAUTIONS

While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.

5.

Remove 12V battery terminal.

CAUTION:

After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)

1.

Unlock the door with intelligent key or remote keyless entry.
NOTE:
At this moment, ACC power is supplied.

2.

Open the driver side door.

3.

Open the hood.

4.

Close the driver side door.

5.

Wait at least 3 minutes.

CAUTION:

While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.

6.

Remove 12V battery terminal.

CAUTION:

After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

PREPARATION

CO-7

< PREPARATION >

[HRA2DDT]

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PREPARATION

PREPARATION

Special Service Tool

INFOID:0000000010505225

NISSAN tool number
(RENAULT too number)
Tool name

Description

WS39930000
(        —       )
Tube pressure

Pressing the tube of liquid gasket

 —
(M.S. 554-07)
Tester

Leak checking
Checking reservoir tank cap

 —
(M.S. 554-01)
Reservoir tank cap tester adapter A

Adapting tester to reservoir tank

 —
(M.S. 554-06)
Reservoir tank cap tester adapter B

Adapting tester to reservoir tank cap

NI. 205
 —
Coolant refill tool

Refilling engine cooling system

S-NT052

MLIA0012E

MLIA0013E

MLIA0014E

LMA053

CO-8

< SYSTEM DESCRIPTION >

[HRA2DDT]

DESCRIPTION

SYSTEM DESCRIPTION

DESCRIPTION

Engine Cooling System

INFOID:0000000010416338

Refer to 

GI-4, "Components"

 for symbol marks in the figure.

1.

Heater core

2.

Water outlet valve

3.

Water outlet air relief plug

4.

Water outlet

5.

Oil cooler

6.

Radiator air relief plug

7.

Radiator

8.

Water inlet and thermostat assembly 9.

Water pump

10. Reservoir tank

11.

Engine 

12. Turbocharger

E1BIA1143ZZ

OVERHEATING CAUSE ANALYSIS

CO-9

< SYMPTOM DIAGNOSIS >

[HRA2DDT]

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SYMPTOM DIAGNOSIS

OVERHEATING CAUSE ANALYSIS

Troubleshooting Chart

INFOID:0000000010416340

Symptom

Check items

Cooling sys-
tem parts 
malfunction

Poor heat transfer

Water pump malfunction

Worn or loose drive belt

Thermostat stuck closed

Damaged fins

Dust contamination or pa-
per clogging

Physical damage

Clogged radiator cooling 
tube

Excess foreign material 
(rust, dirt, sand, etc.)

Reduced air flow

Cooling 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 coolant

Engine coolant leakage

Cooling hose

Loose clamp

Cracked hose

Water pump

Poor sealing

Radiator cap

Loose

Poor sealing

Radiator

O-ring for damage, deterio-
ration or improper fitting

Cracked radiator tank

Cracked radiator core

Reservoir tank

Cracked reservoir tank

Overflowing reservoir tank

Exhaust gas leakage into 
cooling system

Cylinder head deterioration

Cylinder head gasket deteri-
oration

CO-10

< SYMPTOM DIAGNOSIS >

[HRA2DDT]

OVERHEATING CAUSE ANALYSIS

Except cool-
ing system 
parts mal-
function

Overload on engine

Abusive driving

High engine rpm under no 
load

Driving in low gear for ex-
tended time

Driving at extremely high 
speed

Power train system mal-
function

Installed improper size 
wheels and tires

Dragging brakes

Improper ignition timing

Blocked or restricted air 
flow

Blocked bumper

Blocked radiator grille

Installed car brassiere

Mud contamination or paper 
clogging

Blocked radiator

Blocked condenser

Blocked air flow

Installed large fog lamp

Symptom

Check items

ENGINE COOLANT

CO-11

< PERIODIC MAINTENANCE >

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PERIODIC MAINTENANCE

ENGINE COOLANT

Inspection

INFOID:0000000010450832

LEVEL 

• Check if the reservoir tank engine coolant level is within the “MIN”

to “MAX” when the engine is cool.

• Adjust the engine coolant level as necessary.
• Check that the reservoir tank cap is tightened.

WARNING:

Never remove reservoir tank cap when engine is hot. Serious
burns could occur from high-pressure engine coolant escaping
from reservoir tank.

LEAKAGE

• To check for leakage, fit the adapter (A) to the reservoir tank, and

then connect it to the reservoir tank cap tester [SST: — (M.S.554-
07)] (B) as shown.

WARNING:

Never remove reservoir tank cap when engine is hot. Serious
burns could occur from high-pressure engine coolant escap-
ing from reservoir tank.

CAUTION:

Higher test pressure than specified may cause radiator dam-
age.

• If anything is found, repair or replace damaged parts.

Draining

INFOID:0000000010416342

WARNING:

• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine

coolant escaping from radiator. 

• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres-

sure. Then turn it all the way.

1.

Remove engine under cover.

2.

Remove reservoir tank cap.

3.

Open radiator drain plug (1) of radiator. 

CAUTION:

Perform this step when engine is cold.

4.

Remove reservoir tank if necessary, and drain engine coolant
and clean reservoir tank before installing. Refer to 

CO-17,

"Exploded View"

.

5.

Check drained engine coolant for contaminants such as rust,
corrosion or discoloration. If contaminated, flush the engine
cooling system. Refer to 

CO-13, "Flushing"

.

Refilling

INFOID:0000000010416343

CAUTION:

E1BIA1145ZZ

Testing pressure: Refer to 

CO-106, "Radiator"

.

E1BIA1146ZZ

: Vehicle front

E1BIA1139ZZ

CO-12

< PERIODIC MAINTENANCE >

[HRA2DDT]

ENGINE COOLANT

• Never put additive such as waterleak preventive, since it may cause cooling waterway clogging.
• When refilling use Genuine NISSAN Long Life Antifreeze/Coolant (blue) or equivalent in its quality

mixed with water (distilled or demineralized). Refer to 

MA-59, "Fluids and Lubricants"

.

1.

Install reservoir tank if removed and radiator drain plug (1).

CAUTION:

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

2.

Check that each hose clamp has been firmly tightened.

3.

Open radiator air relief plug (1). 

4.

Disconnect heater hose (1) at position (

) in the figure.

• Enhance heater hose as high as possible.

5.

Open water outlet air relief plug (1).

6.

Fill reservoir tank with engine coolant.

CAUTION:

Never adhere the engine coolant to electronic equipments (alternator etc.).
• Pour coolant slowly of less than 3   (2-5/8 Imp qt) per minute to allow air in system to escape.

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ENGINE COOLANT

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7.

When engine coolant spill from radiator air relief plug with continuous flow, close air relief plug and con-
tinue filling reservoir tank. 

8.

When engine coolant spill from water outlet air relief plug with continuous flow, close air relief plug and
continue filling reservoir tank. 

9.

When engine coolant spill from heater hose with continuous
flow, connect heater hose and continue filling reservoir tank until
reach “MAX” level 

10.

11. Install radiator cap.

12. Warm up engine at 3000 rpm until thermostat is opened.

• Check 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 engine.

13. 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.

CAUTION:

Never adhere the engine coolant to electronic equipments (alternator etc.).

14. Refill reservoir tank to “MAX” level line with engine coolant.

15. Repeat steps 11 through 15 two or more times with radiator cap installed until engine coolant level no

longer drops. 

16. Check cooling system for leakage with engine running.

17. Warm up the engine, and check for flowing noise while repeat at least three time slow acceleration from

idle up to 3,000 rpm.

18. If flowing noise is heard, bleed air from cooling system by repeating step 11 through 17 until flowing noise

is no longer heard. 

Flushing

INFOID:0000000010416344

1.

Install reservoir tank if removed and radiator drain plug (1). 

CAUTION:

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

Engine coolant capacity
(With reservoir tank at “MAX” level)

Refer to 

CO-29, "Periodical Maintenance Specifica-

tion"

.

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:  MAX

B

:  MIN

Reservoir tank engine coolant capacity 
(At “MAX” level)

Refer to 

CO-29, "Periodical Maintenance Specification"

.

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E1BIA1139ZZ

CO-14

< PERIODIC MAINTENANCE >

[HRA2DDT]

ENGINE COOLANT

2.

Open radiator air relief plug (1). 

3.

Disconnect heater hose (1) at position (

) in the figure.

• Enhance heater as high as possible.

4.

Open water outlet air relief plug (1). 

5.

Fill reservoir tank with water.
• When engine coolant over flows opened radiator air relief plug, close air relief plug, and continue filling

the engine coolant.

• When engine coolant over flows opened water outlet air relief plug, close air relief plug, and continue fill-

ing the engine coolant.

• When engine coolant over flows disconnected heater hose, connect heater hose, and continue filling the

engine coolant.

6.

Install radiator cap.

7.

Run the engine and warm it up to normal operating temperature.

8.

Rev the engine two or three times under no-load.

9.

Stop the engine and wait until it cools down.

10. Drain water from the system. Refer to 

CO-11, "Draining"

.

11. Repeat steps 1 through 10 until clear water begins to drain from radiator.

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RESERVOIR TANK CAP

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RESERVOIR TANK CAP

Inspection

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• Fit the adapter to the reservoir tank cap tester [SST: — (M.S. 554-

07)] (A) as shown.

• When connecting the reservoir tank cap to the reservoir tank cap

tester, apply water or LLC to the reservoir tank cap seal part.

• Check reservoir tank cap relief pressure.

• Replace the reservoir tank cap if the engine coolant passes

through it, or if any fur signs is detected.

CAUTION:

When installing reservoir tank cap, thoroughly wipe out the res-
ervoir tank filler neck to remove any waxy residue or foreign
material.

Standard: Refer to 

CO-106, "Radiator"

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RADIATOR

RADIATOR

Inspection

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

CAUTION:

• Never bend or damage radiator fins.
• When radiator is cleaned without removal, remove all surrounding parts such as radiator cooling fan

assembly and horns. Then tape harness and harness connectors to prevent water from entering.

1.

Apply water by hose to the back side of the radiator core 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 radiator.

4.

Blow air into the back side of radiator core vertically downward.
• Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm

2

, 71 psi) and keep distance more than 30 cm

(11.81 in). 

5.

Blow air again into all the radiator core surfaces once per minute until no water sprays out.

 

 

 

 

 

 

 

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