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Index of /manuals/AUTOMOBILE/NISSAN/frontier/2006 Frontier

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B ENGINE

SECTION

ENGINE COOLING SYSTEM C

CONTENTS

WATER PUMP ......................................................... 19 F

Removal and Installation ....................................... 19

PRECAUTIONS ......................................................... 3

REMOVAL .......................................................... 19

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

INSPECTION AFTER REMOVAL ...................... 20 G INSTALLATION .................................................. 20

SIONER" ................................................................. 3

INSPECTION AFTER INSTALLATION ............... 20

Precautions for Liquid Gasket ................................. 3 REMOVAL OF LIQUID GASKET SEALING ......... 3

THERMOSTAT AND THERMOSTAT HOUSING ..... 21 Removal and Installation Thermostat .................... 21

LIQUID GASKET APPLICATION PROCEDURE..... 3

REMOVAL .......................................................... 21

PREPARATION .......................................................... 5

INSPECTION AFTER REMOVAL ...................... 21

Special Service Tools .............................................. 5

INSTALLATION .................................................. 22 I

Commercial Service Tools ....................................... 5

INSPECTION AFTER INSTALLATION ............... 22

OVERHEATING CAUSE ANALYSIS ......................... 6

Removal and Installation Water Pump and Ther-

Troubleshooting Chart ............................................. 6

mostat Housing ...................................................... 23 J

COOLING SYSTEM ................................................... 8

REMOVAL .......................................................... 23

Cooling Circuit ......................................................... 8

INSTALLATION .................................................. 23

System Chart .......................................................... 9 ENGINE COOLANT ................................................. 10

INSPECTION AFTER INSTALLATION ............... 23 WATER CONTROL VALVE ...................................... 25

System Check ....................................................... 10

Removal and Installation ....................................... 25

CHECKING COOLING SYSTEM HOSES ......... 10

REMOVAL .......................................................... 25

CHECKING RESERVOIR LEVEL ...................... 10

INSPECTION AFTER REMOVAL ...................... 26 L

CHECKING COOLING SYSTEM FOR LEAKS... 10

INSTALLATION .................................................. 26

CHECKING RESERVOIR CAP .......................... 10 WATER OUTLET AND WATER PIPING .................. 27

CHECKING RADIATOR ......................................11

Removal and Installation ....................................... 27 M

Changing Engine Coolant ......................................11

REMOVAL .......................................................... 27

DRAINING ENGINE COOLANT .........................11

INSTALLATION .................................................. 27

REFILLING ENGINE COOLANT ....................... 12

INSPECTION AFTER INSTALLATION ............... 28

FLUSHING COOLING SYSTEM ........................ 13 SERVICE DATA AND SPECIFICATIONS (SDS) ..... 29

RADIATOR ............................................................... 15

Standard and Limit ................................................. 29

Removal and Installation ....................................... 15

ENGINE COOLANT CAPACITY (APPROXI-

REMOVAL .......................................................... 15

MATE) ................................................................. 29

INSTALLATION .................................................. 17

RESERVOIR CAP .............................................. 29

INSPECTION AFTER INSTALLATION .............. 17

THERMOSTAT ................................................... 29

COOLING FAN ........................................................ 18

Removal and Installation (Crankshaft driven type)... 18 REMOVAL .......................................................... 18

INSPECTION AFTER REMOVAL ...................... 18 PRECAUTIONS ....................................................... 30

INSTALLATION .................................................. 18

Precautions for Supplemental Restraint System

INSPECTION AFTER INSTALLATION .............. 18

(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-

Revision: September 2005

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2006 Frontier

SIONER" ................................................................ 30 Precautions for Liquid Gasket ............................... 30
REMOVAL OF LIQUID GASKET SEALING ....... 30 LIQUID GASKET APPLICATION PROCEDURE... 30 PREPARATION ........................................................ 32 Special Service Tools ............................................ 32 Commercial Service Tools ..................................... 33 OVERHEATING CAUSE ANALYSIS ....................... 34 Troubleshooting Chart ........................................... 34 COOLING SYSTEM ................................................. 36 Cooling Circuit ....................................................... 36 System Chart ......................................................... 37 ENGINE COOLANT ................................................. 38 System Check ....................................................... 38 CHECKING COOLING SYSTEM HOSES .......... 38 CHECKING RESERVOIR LEVEL ...................... 38 CHECKING COOLING SYSTEM FOR LEAKS ... 38 CHECKING RESERVOIR CAP .......................... 38 CHECKING RADIATOR ..................................... 39 Changing Engine Coolant ...................................... 39 DRAINING ENGINE COOLANT ......................... 39 REFILLING ENGINE COOLANT ........................ 41 FLUSHING COOLING SYSTEM ........................ 42 RADIATOR ............................................................... 44 Removal and Installation ....................................... 44 REMOVAL .......................................................... 44 INSTALLATION ................................................... 46 INSPECTION AFTER INSTALLATION ............... 46 ENGINE COOLING FAN .......................................... 47 Removal and Installation (Crankshaft driven type)... 47

REMOVAL ...........................................................47 INSPECTION AFTER REMOVAL .......................47 INSTALLATION ...................................................47 INSPECTION AFTER INSTALLATION ...............47 Removal and Installation (Motor driven type) ........48 REMOVAL ...........................................................48 INSTALLATION ...................................................48 WATER PUMP ..........................................................49 Removal and Installation ........................................49 REMOVAL ...........................................................49 INSPECTION AFTER REMOVAL .......................51 INSTALLATION ...................................................51 INSPECTION AFTER INSTALLATION ...............52 WATER INLET AND THERMOSTAT ASSEMBLY ...54 Removal and Installation ........................................54 REMOVAL ...........................................................54 INSPECTION AFTER REMOVAL .......................54 INSTALLATION ...................................................55 INSPECTION AFTER INSTALLATION ...............55 WATER OUTLET AND WATER PIPING ..................56 Removal and Installation ........................................56 REMOVAL ...........................................................56 INSTALLATION ...................................................56 INSPECTION AFTER INSTALLATION ...............56 SERVICE DATA AND SPECIFICATIONS (SDS) .....58 Standard and Limit .................................................58 ENGINE COOLANT CAPACITY (APPROXIMATE) .................................................................58 RADIATOR ..........................................................58 THERMOSTAT ....................................................58

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PRECAUTIONS

[QR]

PRECAUTIONS

PFP:00001

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT A

BELT PRE-TENSIONER"

EBS00T38

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along CO

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 and SB section of

this Service Manual.

WARNING:

q To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death

in the event of a collision which would result in air bag inflation, all maintenance must be per-

formed by an authorized NISSAN/INFINITI dealer.

q Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-

sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air

Bag Module, see the SRS section.

q 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

harness connectors.

Precautions for Liquid Gasket

EBS00NHD

REMOVAL OF LIQUID GASKET SEALING q After removing nuts and bolts, separate the mating surface, using Tool and remove old liquid gasket seal- G

ing.

Tool number : KV10111100 (J-37228)
CAUTION: Be careful not to damage the mating surfaces.
q Tap Tool to insert it, and then slide it by tapping on the side as shown.
q 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.

H
I
J
WBIA0566E
K

LIQUID GASKET APPLICATION PROCEDURE

1. Remove old liquid gasket adhering to the liquid gasket applica-

tion surface and the mating surface, Using scraper.

q 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.

3. Attach liquid gasket tube to Tool.

PBIC0003E

Revision: September 2005

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PRECAUTIONS
Tool number : WS39930000 ( -- ) Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" . 4. Apply liquid gasket without breaks to the specified location with the specified dimensions. q If there is a groove for the liquid gasket application, apply liq-
uid gasket to the groove.
q 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.
q Within five minutes of liquid gasket application, install the mating component.
q If liquid gasket protrudes, wipe it off immediately. q Do not retighten nuts or bolts after the installation. q After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant. CAUTION: If there are specific instructions in this manual, observe them.

[QR]
WBIA0567E SEM159F

Revision: September 2005

CO-4

2006 Frontier

PREPARATION

[QR]

PREPARATION

Special Service Tools

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

Tool number (Kent-Moore No.) Tool name

Description

PFP:00002
A
EBS00NHE
CO

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

S-NT564

Removing chain tensioner cover and water

pump cover

WS39930000 (--) Tube presser

NT046

Pressing the tube of liquid gasket

-- (J-23688) Engine coolant refractometer

S-NT052

I
Checking concentration of ethylene glycol in engine coolant
J

Commercial Service Tools
Tool name Power tool

WBIA0539E
Description Loosening nuts and bolts

EBS00NGN

Radiator cap tester

PBIC0190E

Checking radiator and radiator cap

PBIC1982E

Revision: September 2005

CO-5

2006 Frontier

OVERHEATING CAUSE ANALYSIS
OVERHEATING CAUSE ANALYSIS Troubleshooting Chart

[QR]
PFP:00012
EBS00NGO

Cooling system parts malfunction

Poor heat transfer

Symptom Water pump malfunction Thermostat and water control valve stuck closed
Damaged fins

Clogged radiator cooling tube

Cooling fan does not operate

Reduced air flow

High resistance to fan rotation

Damaged fan blades

Damaged radiator shroud

Improper engine coolant mixture ratio

Poor engine coolant quality

Engine coolant leaks Insufficient engine coolant
Overflowing reservoir tank

Check items Worn or loose drive belt

Dust contamination or paper clogging

Physical damage

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

Fan assembly

-- -- Engine coolant viscosity Cooling hose Water pump Radiator cap
Radiator
Reservoir tank Exhaust gas leaks into cooling system

--
--
-- Loose clamp Cracked hose Poor sealing Loose Poor sealing O-ring for damage, deterioration or improper fitting Cracked radiator tank Cracked radiator core Cracked reservoir tank Cylinder head deterioration Cylinder head gasket deterioration

Revision: September 2005

CO-6

2006 Frontier

OVERHEATING CAUSE ANALYSIS
[QR]

Symptom

Overload on engine

Except cooling system parts malfunction
Blocked or restricted air flow

Blocked bumper
Blocked radiator grille
Blocked radiator Blocked condenser Installed large fog lamp

Check items
A
High engine rpm under no
load

Abusive driving

Driving in low gear for

extended time

Driving at extremely high

speed

Power train system mal-

function

Installed improper size wheels and tires

Dragging brakes

Improper ignition timing
E
--

Installed car brassiere

Mud contamination or paper clogging
--

F
--

G
Blocked air flow

Revision: September 2005

CO-7

2006 Frontier

COOLING SYSTEM Cooling Circuit

COOLING SYSTEM

[QR]
PFP:21020
EBS00NGP

PBIC3008E

Revision: September 2005

CO-8

2006 Frontier

System Chart

COOLING SYSTEM

[QR]
EBS00NGQ
A

PBIC3009E

Revision: September 2005

CO-9

2006 Frontier

ENGINE COOLANT

[QR]

ENGINE COOLANT

PFP:KQ100

System Check

EBS00NHF

WARNING: q Never remove the radiator cap or reservoir tank cap when the engine is hot. Serious burns could
occur from high pressure fluid escaping from the radiator.
q Wrap a thick cloth around the cap. Slowly push down and turn it a quarter turn to allow built-up pressure to escape. Carefully remove the cap by pushing down and turning it all the way.

CHECKING COOLING SYSTEM HOSES Check hoses for the following: q Improper attachment q Leaks q Cracks q Damage q Loose connections q Chafing q Deterioration

CHECKING RESERVOIR LEVEL q Check if the reservoir tank coolant level is within MIN to MAX
when the engine is cool.
q Adjust engine coolant level as necessary.

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/cm2 , 20 psi)
WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage.

SMA412B WBIA0568E

CHECKING RESERVOIR CAP 1. Inspect the reservoir cap.
q Replace the cap if the metal plunger cannot be seen around the edge of the black rubber gasket.
q 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.

Revision: September 2005

CO-10

2006 Frontier

ENGINE COOLANT
2. Pull the negative-pressure valve to open it and check that it closes completely when released. q Check that there is no dirt or damage on the valve seat of the reservoir cap negative-pressure valve. q Check that there are no abnormalities in the opening and closing conditions of the negative-pressure valve.

[QR]
A CO
C

3. Check reservoir cap relief pressure using Tool.

SMA967B
D

Tool number : EG17650301 (J-33984-A)
E Standard: 98 118 kPa (0.99 1.20 kg/cm2 , 14 17 psi)

q When connecting the reservoir cap to the tester, apply water

or coolant to the cap seal surface.

q Replace the reservoir cap if there is an abnormality in the

negative-pressure valve, or if the open-valve pressure is out-

side of the standard values.

WBIA0570E

CHECKING RADIATOR

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

CAUTION:

q Be careful not to bend or damage the radiator fins. q When radiator is cleaned without removal, remove all surrounding parts such as cooling fan I

shroud and horns. Then tape the harness and electrical connectors to prevent water from enter-

ing.

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. K
4. Blow air into the back side of radiator core, with the air hose pointed vertically downward.

q Use compressed air lower than 490 kPa (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.

6. Check for leaks.

Changing Engine Coolant

M
EBS00T30

WARNING: q To avoid being scalded, never change the coolant when the engine is hot.
q Wrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn to release built-up pressure. Then push down and turn the cap all the way to remove.

DRAINING ENGINE COOLANT 1. Remove the engine undercover using power tool.

Revision: September 2005

CO-11

2006 Frontier

ENGINE COOLANT
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). q Do not to allow the coolant to contact the drive belts.

[QR]

LBIA0063E
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/cm2 ) 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.

KBIA0163E

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 CO-13, "FLUSHING COOLING SYSTEM" .
REFILLING ENGINE COOLANT 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.
q The radiator must be completely empty of coolant and water.
q Apply sealant to the threads of the cylinder block drain plugs. Use Genuine High Performance Thread Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" .

Radiator drain plug

: Refer to CO-15, "RADIATOR" .

Cylinder block drain plug : Refer to EM-75, "CYLINDER BLOCK" .

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.

Revision: September 2005

CO-12

2006 Frontier

ENGINE COOLANT
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. q Use Genuine NISSAN Long Life Anti-freeze coolant or equivalent, mixed 50/50 with distilled water or demineralized water. Refer to MA-13, "ANTI-FREEZE COOLANT MIXTURE RATIO" .

[QR]
A CO
C D

Engine coolant capacity : Refer to MA-11, "Fluids

(with reservoir tank)

and Lubricants" .

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/cm2 , 80 - 120 psi)

CAUTION: The compressed air supply must be equipped with an air

G
LLIA0058E

dryer. 7. The vacuum gauge will begin to rise and there will be an audible hissing noise. During this process open H

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.

I 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 alti-

tude above sea level.

Altitude above sea level 0 - 100 m (328 ft) 300 m (984 ft) 500 m (1,641 ft) 1,000 m (3,281 ft)

Vacuum gauge reading : 28 inches of vacuum : 27 inches of vacuum : 26 inches of vacuum : 24 - 25 inches of vacuum

K
L
LLIA0057E

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 M 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.

FLUSHING COOLING SYSTEM 1. Fill the radiator from the filler cap above the radiator upper hose and reservoir tank, with water and rein-
stall the filler cap above the radiator upper hose.
2. Run the engine until it reaches normal operating temperature.
3. Press the engine accelerator two or three times under no-load.

Revision: September 2005

CO-13

2006 Frontier

ENGINE COOLANT
4. Stop the engine and wait until it cools down. 5. Drain the water. 6. Repeat steps 1 through 5 until clear water begins to drain from the radiator.

[QR]

Revision: September 2005

CO-14

2006 Frontier

RADIATOR Removal and Installation

RADIATOR

[QR]
PFP:21400
A
EBS00NHG
CO

1. Reservoir tank

2. Reservoir tank cap

WBIA0660E

3. Reservoir tank hose

4. Radiator hose (upper)

5. Upper mount bracket

6. Mounting rubber (upper)

7. Radiator cap

8. Radiator

9. Mounting rubber (lower)

10. Radiator hose (lower)

11. Radiator drain plug

12. O-ring

13. A/T fluid cooler hose

14. Upper shroud

15. Lower shroud

16. Heater bypass hose

17. Heater bypass tube

WARNING: Do not remove radiator cap when 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. Drain engine coolant from radiator. Refer to CO-39, "DRAINING ENGINE COOLANT" .
CAUTION: q Perform this step when engine is cold. q Do not spill engine coolant on drive belts. 2. Remove air duct, air duct brackets and air cleaner case assembly. Refer to EM-126, "REMOVAL" . 3. Remove reservoir tank hose. 4. Removal (upper and lower) radiator hoses. CAUTION: Be careful not to allow engine coolant to contact drive belts. 5. Remove radiator cooling fan assembly. Refer to CO-18, "COOLING FAN" .

Revision: September 2005

CO-15

2006 Frontier

RADIATOR
6. Disconnect A/T fluid cooler hoses. (A/T models) q Install blind plug to avoid leakage of A/T fluid.
7. Remove the upper mount bracket bolts.

[QR]

8. Remove the two A/C condenser bolts. (if equipped)

LBIA0419E

9. Remove radiator as follows: CAUTION: Do not damage or scratch A/C condenser and radiator core when removing.
a. With lifting and pulling radiator in a rear direction, disassemble lower mount from radiator core support center. CAUTION: Because A/C condenser is onto the front-lower portion of radiator, moving to rear direction should be at minimum.
b. Lift A/C condenser up and remove radiator after disengaging the fitting as front-bottom surface. CAUTION: Lifting A/C condenser should be minimum to prevent a load to A/C piping.
c. After removing radiator, put A/C condenser on radiator core support center to prevent a load to A/C piping, and temporarily secure it with rope or by similar means.

LBIA0421E PBIC1936E PBIC1054E

Revision: September 2005

CO-16

2006 Frontier

RADIATOR

[QR]

INSTALLATION

Installation is in the reverse order of removal.

INSPECTION AFTER INSTALLATION q Check for leaks of engine coolant using tool. Refer to CO-10, "CHECKING COOLING SYSTEM FOR CO
LEAKS" . q Start and warm up engine. Visually check there are no leaks of engine coolant and A/T fluid.

Revision: September 2005

CO-17

2006 Frontier

COOLING FAN
COOLING FAN Removal and Installation (Crankshaft driven type)

[QR]
PFP:21140
EBS00NHJ

1. Cooling fan 4. Cooling fan pulley

2. Fan coupling

3. Fan bracket

REMOVAL 1. Remove air duct. Refer to EM-126, "REMOVAL" . 2. Remove the engine front undercover. 3. Remove the upper and lower radiator shrouds. Refer to CO-15, "REMOVAL" . 4. Remove drive belts. Refer to EM-124, "Removal" . 5. Remove cooling fan.

INSPECTION AFTER REMOVAL Fan Coupling Inspect fan coupling for oil leakage and bimetal conditions.

WBIA0613E

SLC072
Cooling Fan Inspect cooling fan for crack or unusual bend. q If anything is found, replace cooling fan.
INSTALLATION Installation is in the reverse order of removal. q Install cooling fan with its front mark "F" facing front of engine. Refer to CO-18, "INSTALLATION" .
INSPECTION AFTER INSTALLATION q Check for leaks of the engine coolant using tool. Refer to CO-10, "CHECKING COOLING SYSTEM FOR
LEAKS" . q Start and warm up the engine. Visually make sure that there are no leaks of the engine coolant.

Revision: September 2005

CO-18

2006 Frontier

WATER PUMP Removal and Installation

WATER PUMP

[QR]
PFP:21020
A
EBS00NGZ
CO

1. Gasket 4. Water pump 7. Water inlet 10. Water hose 13. Engine coolant temperature sensor

2. Water outlet

3. Water pump pulley

5. Thermostat

6. O-ring

8. Water pump and thermostat housing 9. Heater pipe

11. Water hose

12. Heater outlet

14. Water control Valve

WBIA0661E
J
K

REMOVAL

1. Drain engine coolant from radiator drain plug at the bottom of radiator and from water drain plug on cylin-

der block. Refer to CO-11, "DRAINING ENGINE COOLANT" and EM-75, "CYLINDER BLOCK" .

CAUTION:

q Perform this step when the engine is cold.

q Do not spill engine coolant on drive belt.

2. Remove air duct; Refer to EM-16, "AIR CLEANER AND AIR DUCT" .

3. Remove drive belt; Refer to EM-14, "DRIVE BELTS" .

4. Remove radiator hose (upper and lower). Refer to CO-15, "RADIATOR" .

5. Remove cooling fan and water pump pulley. Refer to CO-18, "REMOVAL" .

6. Remove water pump with power tool.

CAUTION: q Handle water pump vane so that it does not contact any other parts.

q Water pump cannot be disassembled and should be replaced as a unit.

NOTE: q Engine coolant will leak from cylinder block, so have a receptacle ready below.

Revision: September 2005

CO-19

2006 Frontier

WATER PUMP
INSPECTION AFTER REMOVAL q Visually check if there is no significant dirt or rusting on water
pump body and vane. q Make sure that there is no looseness in vane shaft, and that it
turns smoothly when rotated by hand. q Replace water pump, if necessary.

[QR]

PBIC3011E
INSTALLATION Installation is in the reverse order of removal. q When inserting heater pipe end into water pump and thermostat housing, apply a neutral detergent to O-
ring. Then insert it immediately.
INSPECTION AFTER INSTALLATION q Check for leaks of engine coolant. Refer to CO-10, "CHECKING COOLING SYSTEM FOR LEAKS" . q Start and warm up the engine. Visually check if there is no leaks of engine coolant.

Revision: September 2005

CO-20

2006 Frontier

THERMOSTAT AND THERMOSTAT HOUSING
THERMOSTAT AND THERMOSTAT HOUSING Removal and Installation Thermostat

[QR]
PFP:21200
A
EBS00NH0
CO

1. Gasket 4. Water pump 7. Water inlet 10. Water hose 13. Engine coolant temperature sensor

2. Water outlet

3. Water pump pulley

5. Thermostat

6. O-ring

8. Water pump and thermostat housing 9. Heater pipe

11. Water hose

12. Heater outlet

14. Water control valve

WBIA0661E
J
K

REMOVAL

1. Drain engine coolant. Refer to CO-39, "DRAINING ENGINE COOLANT" and EM-75, "CYLINDER

BLOCK" .

CAUTION:

q Perform this step when the engine is cold.

q Do not spill engine coolant on drive belt.

2. Disconnect radiator hose (lower) at water inlet side. Refer to CO-15, "REMOVAL" .

3. Remove water inlet and thermostat.

INSPECTION AFTER REMOVAL
q Place a thread so that it is caught in the valves of thermostat. Immerse fully in a container filled with water. Heat while stirring.
q The valve opening temperature is the temperature at which the valve opens and falls from the thread.
q Continue heating. Check the maximum valve lift amount.
NOTE: The maximum valve lift amount standard temperature for water control valve is the reference value.
q After checking the maximum valve lift amount, lower the water temperature and check the valve closing temperature.

SLC252B

Revision: September 2005

CO-21

2006 Frontier

THERMOSTAT AND THERMOSTAT HOUSING

Standard:

Items

Thermostat

Valve opening temperature Maximum valve lift Valve closing temperature

80.5 - 83.5°C (177 - 182°F) 8 mm/ 95°C (0.315 in/ 203°F)
77°C (171°F)

q If out of the standard, replace thermostat.

INSTALLATION Installation is in the reverse order of removal.

Thermostat
q Install thermostat with making rubber ring groove fit to thermostat flange with the whole circumference.

[QR]

q Install thermostat with jiggle valve facing upwards. (The position deviation may be within the range of 20° as shown.)

PBIC0157E

INSPECTION AFTER INSTALLATION q Check for leaks of engine coolant. Refer to CO-10, "System Check" . q Start and warm up the engine. Visually check if there is no leaks of engine coolant.

PBIC3013E

Revision: September 2005

CO-22

2006 Frontier

THERMOSTAT AND THERMOSTAT HOUSING Removal and Installation Water Pump and Thermostat Housing

[QR]
EBS00NHQ
A

I
WBIA0661E

1. Gasket

2. Water outlet

3. Water pump pulley

4. Water pump

5. Thermostat

6. O-ring

7. Water inlet

8. Water pump and thermostat housing 9. Heater pipe

10. Water hose

11. Water hose

12. Heater outlet

13. Engine coolant temperature sensor 14. Water control valve

REMOVAL

1. Drain engine coolant. Refer to CO-39, "DRAINING ENGINE COOLANT" .

2. Remove air cleaner and air duct assembly. Refer to EM-16, "REMOVAL" .

3. Remove water pump. Refer to CO-19, "WATER PUMP" .

4. Remove exhaust manifold cover. Refer to EM-21, "EXHAUST MANIFOLD AND THREE WAY CATALYST"

5. Remove oil level gauge and oil level gauge guide. Refer to EM-75, "CYLINDER BLOCK" .

CAUTION: Plug the oil level gauge guide opening to prevent oil pan from entering foreign materials.

6. Remove A/C compressor and position aside. Refer to MTC-102, "Removal and Installation for Compressor" .

7. Remove bolt for heater pipe at water pump and thermostat housing.

8. Disconnect heater pipe from water pump and thermostat housing.

9. Remove water pump and thermostat housing.

INSTALLATION Installation is in the reverse order of removal.
q When inserting heater pipe end into water pump and thermostat housing, apply a neutral detergent to Oring. Then insert it immediately.

INSPECTION AFTER INSTALLATION q Check for leaks of engine coolant. Refer to CO-10, "CHECKING COOLING SYSTEM FOR LEAKS" .

Revision: September 2005

CO-23

2006 Frontier

THERMOSTAT AND THERMOSTAT HOUSING
q Start and warm up the engine. Visually check if there is no leaks of engine coolant.

[QR]

Revision: September 2005

CO-24

2006 Frontier

WATER CONTROL VALVE
WATER CONTROL VALVE Removal and Installation

[QR]
PFP:21230
A
EBS00QAY
CO

WBIA0661E

1. Gasket

2. Water outlet

3. Water pump pulley

4. Water pump

5. Thermostat

6. O-ring

7. Water inlet

8. Water pump and thermostat housing 9. Heater pipe

10. Water hose

11. Water hose

12. Heater outlet

13. Engine coolant temperature sensor 14. Water control valve

WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure

coolant escaping from the radiator.

REMOVAL

CAUTION:

Perform when the engine cold.

1. Drain the engine coolant. Refer to CO-11, "Changing Engine Coolant" .

2. Remove the heater pipe, heater hose and water hoses.

3. Remove the heater outlet.

4. Remove the water control valve.

Revision: September 2005

CO-25

2006 Frontier

WATER CONTROL VALVE
[QR]

INSPECTION AFTER REMOVAL
q Place a thread so that it is caught in the valve of the water control valve. Immerse fully in a container filled with water. Heat while stirring.
q The valve opening temperature is the temperature at which the valve opens and the falls from the thread.
q Continue heating. Check the full-open lift amount.
NOTE: The full-open lift amount standard temperature for the water control valve is the reference value.
q After checking the full-open lift amount, lower the water temperature and check the valve closing temperature.

SLC252B

Standard values

Water Control Valve

Standard Value

Valve opening temperature Full-open lift amount Valve closing temperature

93.5° - 96.5°C (200° - 206°F) More than 8 mm / 108°C (0.315 in / 226° F) 90°C (194° F) or higher

INSTALLATION
Installation is in the reverse order of removal.
q Install the engine coolant temperature sensor if removed. Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
q Install the water control valve with the whole circumference of the flange part fitting securely inside the rubber ring.
q Install the water control valve with the up-mark facing up and the frame center part facing upwards. The position deviation may be within the range of ±10°.

Revision: September 2005

CO-26

2006 Frontier

WATER OUTLET AND WATER PIPING
WATER OUTLET AND WATER PIPING Removal and Installation

[QR]
PFP:11060
A
EBS00NH1
CO

1. Gasket 4. Water pump 7. Water inlet 10. Water hose 13. Engine coolant temperature sensor

2. Water outlet

3. Water pump pulley

5. Thermostat

6. O-ring

8. Water pump and thermostat housing 9. Heater pipe

11. Water hose

12. Heater outlet

14. Water control valve

WBIA0661E
J
K

REMOVAL

1. Drain engine coolant from radiator drain plug at the bottom of radiator, and from water drain plug on the

cylinder block. Refer to CO-11, "DRAINING ENGINE COOLANT" and EM-75, "CYLINDER BLOCK" .

CAUTION:

q Perform this step when engine is cold.

q Do not spill engine coolant on drive belts.

2. Disconnect radiator hose (upper) at water outlet side. Refer to CO-15, "RADIATOR" .

3. Remove water outlet.

4. Disconnect heater hoses and water hoses.

5. Remove heater outlet and water control valve.

6. Remove engine coolant temperature sensor as necessary.

CAUTION: Be careful not to damage engine coolant temperature sensor.

INSTALLATION Note the following, and install in the reverse order of removal. q Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.

Revision: September 2005

CO-27

2006 Frontier

WATER OUTLET AND WATER PIPING
[QR]
INSPECTION AFTER INSTALLATION q Check for leaks of engine coolant using Tool and radiator cap tester (commercial service tool). Refer to
CO-10, "CHECKING COOLING SYSTEM FOR LEAKS" . q Start and warm up engine. Visually make sure that there is no leaks of engine coolant.

Revision: September 2005

CO-28

2006 Frontier

SERVICE DATA AND SPECIFICATIONS (SDS)
[QR]

SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit
ENGINE COOLANT CAPACITY (APPROXIMATE)
Engine coolant capacity (With reservoir tank at "MAX" level)

PFP:00030
A
EBS00NH2
Unit: (US gal, Imp gal) CO
9.4 (2 1/2, 2 1/8)

RESERVOIR CAP
Cap relief pressure Leakage test pressure
THERMOSTAT

Standard

Unit: kPa (kg/cm2 , psi) C
98 - 118 (0.99 - 1.20, 14- 17) 137 (1.4, 20)
D

Valve opening temperature Maximum valve lift Valve closing temperature

80.5 - 83.5°C (177 - 182°F)

8 mm/ 95°C (0.315 in/ 203°F)

77°C (171°F)

Revision: September 2005

CO-29

2006 Frontier

PRECAUTIONS
[VQ]

PRECAUTIONS

PFP:00001

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT

BELT PRE-TENSIONER"

EBS00T39

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 and SB section of this Service Manual.
WARNING: q To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer.
q 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 section.
q 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 harness connectors.

Precautions for Liquid Gasket
REMOVAL OF LIQUID GASKET SEALING

EBS00M62

q 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.
q Tap Tool to insert it, and then slide it by tapping on the side as shown.
q 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.

WBIA0566E

LIQUID GASKET APPLICATION PROCEDURE 1. Remove old liquid gasket adhering to the liquid gasket applica-
tion surface and the mating surface, Using scraper.
q 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.

3. Attach liquid gasket tube to Tool.

PBIC0003E

Revision: September 2005

CO-30

2006 Frontier

[VQ]
A CO
C
WBIA0567E
D E F G
SEM159F
H I J K L M

Revision: September 2005

CO-31

2006 Frontier

PREPARATION
[VQ]

PREPARATION

PFP:00002

Special Service Tools

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

Tool number (Kent-Moore No.) Tool name

Description

EBS00M63

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

S-NT564

Removing chain tensioner cover and water pump cover

WS39930000 (--) Tube presser

NT046
Pressing the tube of liquid gasket

-- (J-23688) Engine coolant refractometer

S-NT052

Checking concentration of ethylene glycol in engine coolant

WBIA0539E

Revision: September 2005

CO-32

2006 Frontier

Commercial Service Tools
Tool name Power tool
Radiator cap tester

PREPARATION
Description Loosening nuts and bolts

[VQ]
EBS00M64
A
CO

C
PBIC0190E
Checking radiator and radiator cap
D

E
PBIC1982E
F

Revision: September 2005

CO-33

2006 Frontier

OVERHEATING CAUSE ANALYSIS
OVERHEATING CAUSE ANALYSIS Troubleshooting Chart

[VQ]
PFP:00012
EBS00M65

Cooling system parts malfunction

Symptom Water pump malfunction Thermostat stuck closed

Poor heat transfer

Damaged fins

Heater pump

Clogged radiator cooling tube

Cooling fan does not operate

Reduced air flow

High resistance to fan rotation

Damaged fan blades

Damaged radiator shroud

Improper engine coolant mixture ratio

Poor engine coolant quality

Engine coolant leaks Insufficient engine coolant
Overflowing reservoir tank

Check items

Worn or loose drive belt

Dust contamination or

paper clogging

Physical damage

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

Fan assembly

-- -- Engine coolant viscosity Cooling hose Water pump Radiator cap
Radiator
Reservoir tank Exhaust gas leaks into cooling system

Revision: September 2005

CO-34

2006 Frontier

OVERHEATING CAUSE ANALYSIS
[VQ]

Symptom

Overload on engine

Except cooling system parts malfunction
Blocked or restricted air flow

Blocked bumper
Blocked radiator grille
Blocked radiator Blocked condenser Installed large fog lamp

Check items
A
High engine rpm under no
load

Abusive driving

Driving in low gear for

extended time

Driving at extremely high

speed

Powertrain system mal-

function

Installed improper size wheels and tires

Dragging brakes

Improper ignition timing
E
--

Installed car brassiere

Mud contamination or paper clogging
--

F
--

G
Blocked air flow

Revision: September 2005

CO-35

2006 Frontier

COOLING SYSTEM Cooling Circuit

COOLING SYSTEM

[VQ]
PFP:21020
EBS00M66

1. Cylinder block (RH) 4. Water pump 7. Thermostat 10. Cylinder block (LH)

2. Oil cooler 5. Radiator 8. Cylinder head (LH)

3. Cylinder head (RH) 6. Water inlet 9. Heater pump

WBIA0641E

Revision: September 2005

CO-36

2006 Frontier

System Chart

COOLING SYSTEM

[VQ]
EBS00M67
A

WBIA0565E

Revision: September 2005

CO-37

2006 Frontier

ENGINE COOLANT
[VQ]

ENGINE COOLANT

PFP:KQ100

System Check

EBS00M68

CHECKING COOLING SYSTEM HOSES Check hoses for the following: q Improper attachment q Leaks q Cracks q Damage q Loose connections q Chafing q Deterioration

CHECKING RESERVOIR LEVEL q Check if the reservoir tank coolant level is within MIN to MAX
when the engine is cool.
q Adjust engine coolant level as necessary.

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/cm2 , 20 psi)
WARNING: Never remove the radiator cap or reservoir tank cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage.

SMA412B WBIA0568E

Revision: September 2005

CO-38

2006 Frontier

ENGINE COOLANT
2. Pull the negative-pressure valve to open it and check that it closes completely when released. q Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve. q Check that there are no abnormalities in the opening and closing conditions of the negative-pressure valve.

[VQ]
A CO
C

3. Check reservoir cap relief pressure using Tool.

SMA967B
D

Tool number : EG17650301 (J-33984-A)
E Standard: 98 118 kPa (0.99 1.20 kg/cm2 , 14 17 psi)

q When connecting the reservoir cap to the tester, apply water

or coolant to the cap seal surface.

q Replace the reservoir cap if there is an abnormality in the

negative-pressure valve, or if the open-valve pressure is out-

side of the standard values.

WBIA0570E

CHECKING RADIATOR

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

CAUTION:

q Be careful not to bend or damage the radiator fins. q When radiator is cleaned without removal, remove all surrounding parts such as cooling fan I

shroud and horns. Then tape the harness and electrical connectors to prevent water from enter-

ing.

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. K
4. Blow air into the back side of radiator core, with the air hose pointed vertically downward.

q Use compressed air lower than 490 kPa (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.

6. Check for leaks.

Changing Engine Coolant

M
EBS00T31

WARNING: q To avoid being scalded, never change the coolant when the engine is hot.
q Wrap a thick cloth around the cap to carefully remove the cap. First, turn the cap a quarter of a turn to release any built-up pressure, then push down and turn the cap all the way to remove it.

DRAINING ENGINE COOLANT 1. Turn ignition switch ON and set temperature control lever all the way to HOT position or the highest tem-
perature position. Wait 10 seconds and turn ignition switch OFF.
2. Remove the engine front undercover using power tool.

Revision: September 2005

CO-39

2006 Frontier

ENGINE COOLANT
3. Open the radiator drain plug at the bottom of the radiator, and remove the reservoir cap. This is the only step required when partially draining the cooling system (radiator only). CAUTION: Do not to allow the coolant to contaminate the drive belts.
4. When draining all of the coolant in the system for engine removal or repair, it is necessary to drain the cylinder block. Remove the cylinder block drain plugs, and block heater if equipped, to drain the cylinder block as shown. NOTE: For Canada, the "D" cylinder block drain plug as shown, is not a cylinder block drain plug but a block heater.

[VQ]
LLIA0070E

WLIA0020E
5. Remove the reservoir tank to drain the engine coolant, then clean the reservoir tank before installing it. 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 CO-42, "FLUSHING COOLING SYSTEM" .

Revision: September 2005

CO-40

2006 Frontier

ENGINE COOLANT
REFILLING ENGINE COOLANT 1. Close the radiator drain plug. Install the reservoir tank, cylinder
block drain plugs, and block heater if equipped, if removed for a total system drain or for engine removal or repair. q The radiator must be completely empty of coolant and water. q Apply sealant to the threads of the cylinder block drain plug.
Use Genuine High Performance Thread Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" .

[VQ]
A CO
C D

Block Plug and Block Heater Installation

WLIA0020E
H

Part

Washer

Tightening Torque

Reuse

New

19.6 N·m (2.0 kg-m, 14 ft-lb)
I
9.8 N·m (1.0 kg-m, 87 in-lb) 6.0 N·m (0.61 kg-m, 53 in-lb)

Yes

62 N·m (6.3 kg-m, 46 ft-lb)

Plug

Yes

Block heater

62 N·m (6.3 kg-m, 46 ft-lb) 73.5 N·m (7.5 kg-m, 54 ft-lb)

K 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.

3. Remove the vented reservoir cap and replace it with a non-vented reservoir cap before filling the cooling system.

Revision: September 2005

CO-41

2006 Frontier

[VQ]

Cooling system capacity : Refer to MA-11, "Fluids

(with reservoir)

and Lubricants" .

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/cm2 , 80 - 120 psi)

CAUTION: The compressed air supply must be equipped with an air dryer.

LLIA0058E

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 0 - 100 m (328 ft) 300 m (984 ft) 500 m (1,641 ft) 1,000 m (3,281 ft)

Vacuum gauge reading : 28 inches of vacuum : 27 inches of vacuum : 26 inches of vacuum : 24 - 25 inches of vacuum

LLIA0057E

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 and install the radiator cap.
12. Remove the reservoir cap.
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.

FLUSHING COOLING SYSTEM 1. Drain the water from the engine cooling system. Refer to CO-39, "DRAINING ENGINE COOLANT" .
2. Fill the radiator and the reservoir tank (to the "MAX" line), with water. Reinstall the radiator cap and leave the vented reservoir cap off.

Revision: September 2005

CO-42

2006 Frontier

ENGINE COOLANT
[VQ]

3. Run the engine until it reaches normal operating temperature.

4. Press the engine accelerator two or three times under no-load.

5. Stop the engine and wait until it cools down.

6. Drain the water from the engine cooling system. Refer to CO-39, "DRAINING ENGINE COOLANT" .

7. Repeat steps 2 through 6 until clear water begins to drain from the radiator.

Revision: September 2005

CO-43

2006 Frontier

RADIATOR Removal and Installation

RADIATOR

[VQ]
PFP:21400
EBS00M6A

1. Reservoir tank 4. Radiator hose (upper) 7. Radiator cap 10. Radiator drain plug 13. Radiator hose (lower)

2. Reservoir tank cap 5. Upper mount bracket 8. Radiator 11. O-ring 14. Heater bypass tube

3. Reservoir tank hose 6. Mounting rubber (upper) 9. Mounting rubber (lower) 12. A/T fluid cooler hose 15. Heater bypass hose

LBIA0418E

REMOVAL 1. Remove engine cover with power tool. Refer to EM-123, "REMOVAL" . 2. Drain engine coolant from radiator. Refer to CO-39, "DRAINING ENGINE COOLANT" .
CAUTION: q Perform this step when engine is cold. q Do not spill engine coolant on drive belts. 3. Remove air duct and air cleaner case assembly. Refer to EM-126, "REMOVAL" . 4. Remove reservoir tank hose. 5. Removal (upper and lower) radiator hoses. CAUTION: Be careful not to allow engine coolant to contact drive belts. 6. Remove radiator cooling fan assembly. Refer to CO-18, "REMOVAL" .

Revision: September 2005

CO-44

2006 Frontier

RADIATOR
7. Disconnect A/T fluid cooler hoses. (A/T models) q Install blind plug to avoid leakage of A/T fluid.
8. Remove the upper mount bracket bolts.
9. Remove the two A/C condenser bolts.
10. Remove radiator as follows: CAUTION: Do not damage or scratch A/C condenser and radiator core when removing.
a. With lifting and pulling radiator in a rear direction, disassemble lower mount from radiator core support center. CAUTION: Because A/C condenser is onto the front-lower portion of radiator, moving to rear direction should be at minimum.
b. Lift A/C condenser up and remove radiator after disengaging the fitting as front-bottom surface. CAUTION: Lifting A/C condenser should be minimum to prevent a load to A/C piping.
c. After removing radiator, put A/C condenser on radiator core support center to prevent a load to A/C piping, and temporarily fix it with rope or similar means.

[VQ]
A

D
LBIA0419E
E

LBIA0421E

L
PBIC1936E
M

PBIC1054E

Revision: September 2005

CO-45

2006 Frontier

RADIATOR
[VQ]
INSTALLATION Installation is in the reverse order of removal.
INSPECTION AFTER INSTALLATION q Check for leaks of engine coolant using tool. Refer to CO-10, "CHECKING COOLING SYSTEM FOR
LEAKS" . q Start and warm up engine. Visually check there are no leaks of engine coolant and A/T fluid.

Revision: September 2005

CO-46

2006 Frontier

ENGINE COOLING FAN
ENGINE COOLING FAN Removal and Installation (Crankshaft driven type)

1. Cooling fan 4. Cooling fan pulley

2. Fan coupling

3. Fan bracket

REMOVAL 1. Remove air duct. Refer to EM-126, "REMOVAL" . 2. Remove the engine front undercover. 3. Remove the upper and lower radiator shrouds. Refer to CO-44, "REMOVAL" . 4. Remove drive belts. Refer to EM-126, "REMOVAL" . 5. Remove cooling fan.

INSPECTION AFTER REMOVAL Fan Coupling Inspect fan coupling for oil leakage and bimetal conditions.

Fan Bracket
q Visually check that there is no significant looseness in the fan bracket shaft, and that it turns smoothly by hand.
q If there are any unusual concerns, replace the fan bracket assembly.

[VQ]
PFP:21140
A
EBS00M6B
CO

D
WBIA0575E
E

SLC072

LBIA0422E
INSTALLATION Installation is in the reverse order of removal. q Install cooling fan with its front mark "F" facing front of engine.
INSPECTION AFTER INSTALLATION q Check for leaks of the engine coolant using tool. Refer to CO-38, "CHECKING COOLING SYSTEM FOR
LEAKS" .

Revision: September 2005

CO-47

2006 Frontier

ENGINE COOLING FAN
q Start and warm up the engine. Visually make sure that there are no leaks of the engine coolant.
Removal and Installation (Motor driven type)
REMOVAL 1. Remove radiator upper and lower shroud. Refer to CO-44,
"REMOVAL" . 2. Disconnect harness connector from fan motor. 3. Remove the bolt and remove the fan grille and motor assembly.

[VQ]
EBS00M6C

LBIA0423E
INSTALLATION Installation is in the reverse order of removal.
Engine coolant fan bolt : 4.9 N·m (0.50 kg-m, 43 in-lb)
q Cooling fan is controlled by ECM. For details, refer to EC-1104, "DTC P1217 ENGINE OVER TEMPERATURE" .

Revision: September 2005

CO-48

2006 Frontier

WATER PUMP Removal and Installation

WATER PUMP

[VQ]
PFP:21020
A
EBS00M6D
CO

1. Water pump 4. Water drain plug (front) 7. O-ring

G
PBIC2833E

2. Timing chain tensioner (primary)

3. Chain tensioner cover

5. Water pump cover

6. O-ring

CAUTION:

q When removing water pump assembly, be careful not to get engine coolant on drive belts.

q Water pump cannot be disassembled and should be replaced as a unit.

q After installing water pump, connect hose and clamp securely, then check for leaks using tool. J
REMOVAL

1. Remove undercover with power tool.

2. Remove drive belts. Refer to EM-124, "Removal" .

3. Drain engine coolant. Refer to CO-39, "DRAINING ENGINE COOLANT" .

CAUTION:

q Perform this step when engine is cold.

q Do not spill engine coolant on drive belts.

4. Remove radiator hoses (upper and lower) and cooling fan assembly. Refer to CO-44, "REMOVAL" .

5. Remove chain tensioner cover and water pump cover from front

timing chain case, using Tool.

Tool number : KV10111100 (J-37228)

PBIC2662E

Revision: September 2005

CO-49

2006 Frontier

WATER PUMP
6. Remove timing chain tensioner (primary) as follows: a. Loosen clip of timing chain tensioner (primary), and release
plunger stopper. (1) b. Insert plunger into tensioner body by pressing slack guide. (2) c. Keep slack guide pressed and hold plunger in by pushing stop-
per pin through the tensioner body hole and plunger groove. (3)
d. Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose.
e. Remove bolts and remove timing chain tensioner (primary). CAUTION: Be careful not to drop bolts inside timing chain case.
7. Remove water pump as follows: a. 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.

Revision: September 2005

CO-50

[VQ]
PBIC2835E PBIC2834E PBIC2836E PBIC2863E
2006 Frontier

WATER PUMP
b. 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: q Pull straight out while preventing vane from contacting socket in installation area. q Remove water pump without causing sprocket to contact timing chain.
c. Remove M8 bolts and O-rings from water pump. CAUTION: Do not disassemble water pump. NOTE: Do not reuse O-rings.
INSPECTION AFTER REMOVAL q Check for badly rusted or corroded water pump body assembly. q Check for rough operation due to excessive end play. q Replace water pump, if necessary.
INSTALLATION 1. Install new O-rings to water pump.
NOTE: q Apply engine oil to new O-rings. q Locate new O-ring with white paint mark to engine front side.

2. Install water pump.
CAUTION: Do not allow timing chain case to nip O-rings when install water pump.
q Make sure that timing chain and water pump sprocket are engaged.
q Insert water pump by tightening bolts alternately and evenly.

3. Install timing chain tensioner (primary) as follows:

Revision: September 2005

CO-51

[VQ]
A

C
JLC357B
D

G H

SLC943A

M
PBIC2837E

PBIC1058E
2006 Frontier

WATER PUMP
[VQ]
a. Remove dust and foreign material completely from backside of timing chain tensioner (primary) and from installation area of rear timing chain case.
b. Turn crankshaft pulley clockwise so that timing chain on the timing chain tensioner (primary) side is loose. c. Install timing chain tensioner (primary) with its stopper pin attached.
CAUTION: Be careful not to drop bolts inside timing chain case. d. Remove stopper pin.

e. Make sure again that timing chain and water pump sprocket are engaged.
4. Install chain tensioner cover and water pump cover as follows:
a. 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.

PBIC2838E

SLC446B
b. 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 GI-48, "Recommended Chemical Products and Sealants" . CAUTION: Attaching should be done within 5 minutes after coating. c. Tighten bolts to specified torque. Refer to CO-49, "Removal and Installation" .

PBIC2663E

5. Refill engine coolant system. Refer to CO-41, "REFILLING ENGINE COOLANT" .
q Apply liquid gasket to the thread of water drain plug (front). Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-48, "Recommended Chemical Products and Sealants" .
6. Installation of the remaining components is in the reverse order of removal after this step.
q 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.
INSPECTION AFTER INSTALLATION
q Check for leaks of engine coolant using tool. Refer to CO-38, "CHECKING COOLING SYSTEM FOR LEAKS" .

Revision: September 2005

CO-52

2006 Frontier

WATER PUMP
q Start and warm up engine. Visually check there are no leaks of engine coolant.

[VQ]
A CO
C D E F G H I J K L M

Revision: September 2005

CO-53

2006 Frontier

WATER INLET AND THERMOSTAT ASSEMBLY
WATER INLET AND THERMOSTAT ASSEMBLY Removal and Installation

[VQ]
PFP:21200
EBS00M6E

1. Water inlet and thermostat assembly 2. Gasket

PBIC2839E

REMOVAL 1. Completely drain engine coolant. Refer to CO-39, "DRAINING ENGINE COOLANT" .
CAUTION: q Perform this step when engine is cold.
q Do not spill engine coolant on drive belts.
2. Remove air duct and air cleaner case. Refer to EM-126, "REMOVAL" . 3. Disconnect radiator hose (lower) and oil cooler hose from water inlet and thermostat assembly.
4. Remove water inlet and thermostat assembly.
CAUTION: Do not disassemble water inlet and thermostat assembly. Replace them as a unit, if necessary.

INSPECTION AFTER REMOVAL 1. Check valve seating condition at ordinary room temperatures. It should seat tightly. 2. Check valve operation.

Thermostat

Standard

Valve opening temperature

80.5 - 83.5°C (177 - 182°F)

Maximum valve lift

8.6 mm / 95°C (0.339 in / 203°F)

Valve closing temperature

77°C (171°F)

q If the malfunctioning condition, when valve seating at ordinary room temperature, or measured values are out of the standard, replace water inlet and thermostat assembly.

Revision: September 2005

CO-54

SLC962AB
SLC949A
2006 Frontier

WATER INLET AND THERMOSTAT ASSEMBLY
[VQ]

INSTALLATION

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

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

INSPECTION AFTER INSTALLATION

q Check for leaks of engine coolant using tool. Refer to CO-38, "CHECKING COOLING SYSTEM FOR

LEAKS" .

q Start and warm up engine. Visually check there are no leaks of engine coolant.

Revision: September 2005

CO-55

2006 Frontier

WATER OUTLET AND WATER PIPING
WATER OUTLET AND WATER PIPING Removal and Installation

[VQ]
PFP:11060
EBS00M6F

1. Engine coolant temperature sensor 4. Heater hose 7. Water hose 10. Water hose 13. Heater hose

2. Washer 5. O-ring 8. Radiator hose (upper) 11. Gasket 14. Gasket

3. Water outlet 6. Water pipe 9. Water hose 12. Heater pipe

WBIA0615E

REMOVAL 1. Completely drain engine coolant. Refer to CO-39, "DRAINING ENGINE COOLANT" .
CAUTION: q Perform this step when engine is cold. q Do not spill engine coolant on drive belts. 2. Remove A/T fluid charging pipe. Refer to AT-252, "REMOVAL" (4X2) or AT-254, "REMOVAL" (4X4) 3. Remove the rocker cover (right bank). Refer to EM-153, "REMOVAL (Right bank)" . 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 Installation is in the reverse order of removal, paying attention to the following. q Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge. q When inserting water pipe into water outlet, apply neutral detergent to O-ring.

INSPECTION AFTER INSTALLATION
q Check for leaks of engine coolant using tool. Refer to CO-38, "CHECKING COOLING SYSTEM FOR LEAKS" .

Revision: September 2005

CO-56

2006 Frontier

WATER OUTLET AND WATER PIPING
q Start and warm up engine. Visually check there are no leaks of engine coolant.

[VQ]
A CO
C D E F G H I J K L M

Revision: September 2005

CO-57

2006 Frontier

SERVICE DATA AND SPECIFICATIONS (SDS)
[VQ]

SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit
ENGINE COOLANT CAPACITY (APPROXIMATE)
Engine coolant capacity (With reservoir tank at "MAX" level)

PFP:00100
EBS00M6G
Unit: (US gal, Imp gal) 10.2 (2-3/4, 2-1/4)

RADIATOR
Cap relief pressure Leakage testing pressure

Standard

Unit: kPa (kg/cm2 , psi) 98 - 118 (0.99 - 1.20, 14 - 17)
137 (1.4, 20)

THERMOSTAT

Valve opening temperature Maximum valve lift valve closing temperature

80.5 - 83.5°C (177 - 182°F) 8.6 mm / 95°C (0.339 in / 203°F)
77°C (171°F)

Revision: September 2005

CO-58

2006 Frontier

FrameMaker SGML 5.5.6p145 Acrobat Distiller 4.05 for Windows