ENGINE

ENGINE COOLING SYSTEM

SECTION CO CO

E
CONTENTS
SYSTEM DESCRIPTION .............................. 2 REMOVAL AND INSTALLATION ............... 14 F

DESCRIPTION .................................................... 2 RADIATOR ........................................................ 14

Engine Cooling System ........................................... 2 Exploded View .........................................................14 G
Engine Cooling System Schematic ......................... 2 Removal and Installation .........................................15
Inspection ................................................................16
SYMPTOM DIAGNOSIS ............................... 3
COOLING FAN .................................................. 17 H
OVERHEATING CAUSE ANALYSIS .................. 3 Exploded View .........................................................17
Troubleshooting Chart .............................................. 3 Removal and Installation .........................................17
Inspection ................................................................17 I
PRECAUTION ............................................... 5 Disassembly and Assembly .....................................17
PRECAUTIONS ................................................... 5 Inspection ................................................................18
Precaution for Supplemental Restraint System WATER PUMP .................................................. 19 J
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Exploded View .........................................................19
SIONER" ................................................................... 5 Removal and Installation .........................................19
Liquid Gasket ........................................................... 5 Inspection ................................................................21 K
PREPARATION ............................................ 7 WATER INLET AND THERMOSTAT ASSEM-
PREPARATION ................................................... 7 BLY .................................................................... 22
L
Exploded View .........................................................22
Commercial Service Tools ....................................... 7
Removal and Installation .........................................22
PERIODIC MAINTENANCE .......................... 8 Inspection ................................................................23
M
ENGINE COOLANT ............................................ 8 WATER OUTLET AND WATER PIPING .......... 24
Inspection .................................................................. 8 Exploded View .........................................................24
Draining ..................................................................... 8 Removal and Installation .........................................24 N
Refilling ..................................................................... 9 Inspection ................................................................25
Flushing ................................................................... 10
SERVICE DATA AND SPECIFICATIONS
RADIATOR .........................................................12 (SDS) ............................................................ 26 O

RADIATOR CAP ........................................................ 12 SERVICE DATA AND SPECIFICATIONS

RADIATOR CAP : Inspection .................................. 12 (SDS) ................................................................. 26 P
Periodical Maintenance Specification ....................26
RADIATOR ................................................................ 12
Radiator ...................................................................26
RADIATOR : Inspection .......................................... 12
Thermostat ..............................................................26

Revision: 2008 September CO-1 2008 G35 Sedan

 DESCRIPTION
< SYSTEM DESCRIPTION >
SYSTEM DESCRIPTION
DESCRIPTION
Engine Cooling System INFOID:0000000001835812

JPBIA0248GB

Engine Cooling System Schematic INFOID:0000000001835813

JPBIA0249GB

Revision: 2008 September CO-2 2008 G35 Sedan

 OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart INFOID:0000000001835814
CO

Symptom Check items

C
Water pump malfunction Worn or loose drive belt
Thermostat stuck closed —
Dust contamination or pa- D
Poor heat transfer Damaged fins per clogging —
Physical damage
Clogged radiator cooling Excess foreign material E
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
ate F
Reduced air flow High resistance to fan rota- Fan assembly —
tion
Damaged fan blades G
Damaged radiator shroud — — —
Improper engine coolant
Cooling sys- — — — H
mixture ratio
tem parts
malfunction Poor engine coolant quality — Engine coolant density —
Loose clamp
Cooling hose I
Cracked hose
Water pump Poor sealing
Loose J
Radiator cap
Poor sealing
Engine coolant leaks
O-ring for damage, deterio-
Insufficient engine coolant ration or improper fitting K
Radiator
Cracked radiator tank
Cracked radiator core
L
Reservoir tank Cracked reservoir tank
Cylinder head deterioration
Exhaust gas leaks into cool-
Overflowing reservoir tank Cylinder head gasket deteri- M
ing system
oration

Revision: 2008 September CO-3 2008 G35 Sedan

 OVERHEATING CAUSE ANALYSIS
< SYMPTOM DIAGNOSIS >
Symptom Check items
High engine rpm under no
load
Driving in low gear for ex-
Abusive driving
tended time
Driving at extremely high
speed
— Overload on engine
Powertrain system malfunc-
tion
Installed improper size
Except cool- —
wheels and tires
ing system
parts mal- Dragging brakes
function
Improper ignition timing
Blocked bumper —
Installed car brassiere
Blocked radiator grille Mud contamination or paper
Blocked or restricted air clogging —
flow
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp

Revision: 2008 September CO-4 2008 G35 Sedan

 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT CO
PRE-TENSIONER" INFOID:0000000001835815

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. D
Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this
Service Manual.
WARNING: E
• 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.
F
• 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 G
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS H
WARNING:
• 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) I
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 J
battery, and wait at least 3 minutes before performing any service.
Liquid Gasket INFOID:0000000001835816

K
REMOVAL OF LIQUID GASKET SEALING
• After removing mounting nuts and bolts, separate the mating sur-
face using the seal cutter [SST: KV10111100 (J37228)] (A) and L
remove old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
• Tap (B) the seal cutter [SST: KV10111100 (J37228)] to insert it, and M
then slide (C) it by tapping on the side as shown in the figure.
• In areas where seal cutter [SST: KV10111100 (J38228)] is difficult
to use, use a plastic hammer to lightly tap the parts, to remove it. N
CAUTION:
If for some unavoidable reason tool such as a screwdriver is
JPBIA0052ZZ
used, be careful not to damage the mating surfaces.
O
LIQUID GASKET APPLICATION PROCEDURE

Revision: 2008 September CO-5 2008 G35 Sedan

 PRECAUTIONS
< PRECAUTION >
1. Using a scraper (A), remove old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
• Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.

JPBIA0053ZZ

3. Attach liquid gasket tube to the tube presser (commercial ser-

vice tool).
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-15, "Recommended Chemical Products and Sealants".
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions.
• If there is a groove for the liquid gasket application, apply liq-
uid gasket to the groove.

EMA0622D

• As for the bolt holes (B), normally apply liquid gasket inside
the holes. Occasionally, it should be applied outside the holes.
Check to read the text of service manual.

A : Groove
: Inside

• Within five minutes of liquid gasket application, install the mat-

ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Do not retighten after mounting bolts and nuts the installation.
JPBIA0010ZZ
• 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.

Revision: 2008 September CO-6 2008 G35 Sedan

 PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Commercial Service Tools INFOID:0000000001835818
CO

Tool name Description

C
Tube presser Pressing the tube of liquid gasket

E
S-NT052

Power tool Loosening nuts and bolts

PBIC0190E

Radiator cap tester Checking radiator and radiator cap H

PBIC1982E J
Radiator cap tester adapter Adapting radiator cap tester to radiator cap
and water outlet (front) filler neck
a: 28 (1.10) dia.
K
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
L
S-NT564

Revision: 2008 September CO-7 2008 G35 Sedan

 ENGINE COOLANT
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE
ENGINE COOLANT
Inspection INFOID:0000000001835819

LEVEL
• Check if the reservoir tank engine coolant level is within the “MIN”
to “MAX” when the engine is cool.

A : MAX
B : MIN
• Adjust the engine coolant level as necessary.
• Check that the reservoir tank cap is tightened.

JPBIA0102ZZ

LEAKAGE
• To check for leaks, apply pressure to the cooling system with the
radiator cap tester and radiator cap tester adapter (commercial
service tool) (A).

Testing pressure : Refer to CO-26, "Radiator".

WARNING:
Never remove radiator cap when engine is hot. Serious burns
could occur from high-pressure engine coolant escaping from
radiator.
CAUTION:
Higher test pressure than specified may cause radiator dam- JPBIA0411ZZ

age.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
• If anything is found, repair or replace damaged parts.
Draining INFOID:0000000001835820

WARNING:
• To avoid being scalded, never change engine coolant when the engine is hot.
• Wrap a thick cloth around radiator cap and carefully remove radiator cap. First, turn radiator cap a
quarter of a turn to release built-up pressure. Then turn radiator cap all the way.
1. Open radiator drain plug (2) at the bottom of radiator, and then remove radiator cap.

1 : Engine under cover

A : Radiator drain plug hole
: Vehicle front

JPBIA0259ZZ

When draining all of engine coolant in the system, open water drain plugs on cylinder block. Refer
to EM-89, "Setting".

2. Remove reservoir tank as necessary, and drain engine coolant and clean reservoir tank before installing.

Revision: 2008 September CO-8 2008 G35 Sedan

 ENGINE COOLANT
< PERIODIC MAINTENANCE >
3. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush the engine cooling system. Refer to CO-10, "Flushing". A
Refilling INFOID:0000000001835821

1. Remove air cleaner case (LH). Refer to EM-26, "Exploded View". CO

2. Install reservoir tank if removed, and radiator drain plug.
CAUTION:
Be sure to clean drain plug and install with new O-ring. C

Tightening torque : Refer to CO-14, "Exploded View".

If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-117, "Dis- D
assembly and Assembly".
3. Check that each hose clamp has been firmly tightened.
E
4. Remove air relief plug (2) on radiator left side.

1 : Reservoir tank
3 : Engine cover
F
: Vehicle front

H
JPBIA0260ZZ

5. Remove air relief plug (1) on heater hose.

I
2 : Heater hose
: Vehicle front
J

L
JPBIA0104ZZ

6. Fill radiator, and reservoir tank if removed, to specified level.

• Pour engine coolant through engine coolant filler neck M
slowly of less than 2 (2-1/8 US qt, 1-3/4 lmp qt) a minute
to allow air in system to escape.
• Use Genuine NISSAN Long Life Antifreeze/Coolant or
equivalent mixed with water (distilled or demineralized). N
Refer to MA-10, "Fluids and Lubricants".

Engine coolant capacity : Refer to CO-26, O

(With reservoir tank at "Periodical Maintenanc
“MAX” level) e Specification". JPBIA0412ZZ

Reservoir tank engine coolant capacity :Refer to CO-26,

(At “MAX” level) "Periodical Maintenance Specification".

Revision: 2008 September CO-9 2008 G35 Sedan

 ENGINE COOLANT
< PERIODIC MAINTENANCE >

A : MAX
B : MIN
7. When engine coolant overflows air relief hole on radiator, install
air relief plug with new O-ring.

Tightening torque : Refer to CO-14, "Exploded View".

JPBIA0102ZZ

8. Repeat step 6.
9. When engine coolant overflows air relief hole on heater hose, install air relief plug with new O-ring. Then
refill radiator with engine coolant.

: 1.2 N·m (0.12 kg-m, 11 in-lb)

10. Install air cleaner case (LH). Refer to EM-26, "Exploded View".
11. Install radiator cap.
12. Warm up engine until opening thermostat. Standard for warming-up time is approximately 10 minutes at
3,000 rpm.
• 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.
14. Refill reservoir tank to “MAX” level line with engine coolant.
15. Repeat steps 11 through 14 two or more times with radiator cap installed until engine coolant level no
longer drops.
16. Check cooling system for leaks with engine running.
17. Warm up the engine, and check for sound of engine coolant flow while running engine from idle up to
3,000 rpm with heater temperature controller set at several position between “COOL” and “WARM”.
• Sound may be noticeable at heater unit.
18. Repeat step 17 three times.
19. If sound is heard, bleed air from cooling system by repeating step 6, and steps from 11 to 18 until engine
coolant level no longer drops.
20. Check that the reservoir tank cap is tightened.
Flushing INFOID:0000000001835822

1. Install reservoir tank if removed, and radiator drain plug.

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

Tightening torque : Refer to CO-14, "Exploded View".

If water drain plugs on cylinder block are removed, close and tighten them. Refer to EM-117, "Dis-
assembly and Assembly".

Revision: 2008 September CO-10 2008 G35 Sedan

 ENGINE COOLANT
< PERIODIC MAINTENANCE >
2. Remove air relief plug (1) on heater hose.
A
2 : Heater hose
: Vehicle front
CO

JPBIA0104ZZ

D
3. Remove air relief plug (2) on radiator.

1 : Reservoir tank E
3 : Engine cover
: Vehicle front
F

G
JPBIA0260ZZ

4. Fill radiator with water until water spills from the air relief holes, then close air relief plugs. Fill radiator and H
reservoir tank with water and reinstall radiator cap.

Tightening torque : Refer to CO-14, "Exploded View". I

5. Run the engine and warm it up to normal operating temperature.
6. Rev the engine two or three times under no-load.
7. Stop the engine and wait until it cools down. J
8. Drain water from the system. Refer to CO-8, "Draining".
9. Repeat steps 1 through 8 until clear water begins to drain from radiator.
K
10. Check that the reservoir tank cap is tightened.

Revision: 2008 September CO-11 2008 G35 Sedan

 RADIATOR
< PERIODIC MAINTENANCE >
RADIATOR
RADIATOR CAP
RADIATOR CAP : Inspection INFOID:0000000001835823

• Check valve seat of radiator cap.

- Check if valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
- Check if valve seat has no soil and damage.

A : Valve seat
B : Metal plunger

JPBIA0108ZZ

• Pull negative-pressure valve to open it, and check that it close

completely when released.
- Check that there is no dirt or damage on the valve seat of radiator
cap negative-pressure valve.
- Check that there are no unusualness in the opening and closing
conditions of negative-pressure valve.

SMA967B

• Check radiator cap relief pressure.

Standard and limit : Refer to CO-26, "Radiator".

- When connecting radiator cap to the radiator cap tester (commer-
cial service tool) and the radiator cap tester adapter (commercial
service tool) (A), apply engine coolant to the cap seal surface.

JPBIA0109ZZ

• Replace radiator cap if there is an unusualness related to the above three.

CAUTION:
When installing radiator cap, thoroughly wipe out the water outlet (front) filler neck to remove any
waxy residue or foreign material.
RADIATOR
RADIATOR : Inspection INFOID:0000000001835824

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

• Be careful not to bend or damage radiator fins.
• When radiator is cleaned without removal, remove all surrounding parts such as radiator cooling fan assem-
bly and horns. Then tape harness and 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.

Revision: 2008 September CO-12 2008 G35 Sedan

 RADIATOR
< PERIODIC MAINTENANCE >
• 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. A

CO

Revision: 2008 September CO-13 2008 G35 Sedan

 RADIATOR
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
RADIATOR
Exploded View INFOID:0000000001835825

JPBIA1515GB

1. Upper mount bracket 2. Mounting rubber (upper) 3. Radiator & condenser assembly
4. Condenser pipe assembly 5. O-ring 6. O-ring
7. Clamp 8. A/T fluid cooler hose (A/T models) 9. A/T fluid cooler hose (A/T models)
10. Mounting rubber (lower) 11. Clamp 12. Radiator hose (lower)
13. Radiator hose (Upper) 14. Water drain hose 15. Drain plug
16. O-ring 17. Radiator water inlet pipe 18. O-ring
19. O-ring 20. Air relief plug 21. Reservoir tank cap
22. Reservoir tank 23. Reservoir tank hose 24. Clamp
25. Reservoir tank hose 26. Grommet 27. Radiator cooling fan assembly
A. To transmission B. To water inlet C. To water outlet
D. Refer to HA-49
Refer to GI-4, "Components" for symbols in the figure.

Revision: 2008 September CO-14 2008 G35 Sedan

 RADIATOR
< REMOVAL AND INSTALLATION >
Removal and Installation INFOID:0000000001835826

A
REMOVAL
WARNING:
Never remove radiator cap when engine is hot. Serious burns could occur from high-pressure engine CO
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.
1. Remove the following parts: C
• Engine under cover with power tool.
• Engine cover: Refer to EM-28, "Exploded View".
• Air cleaner case (RH and LH): Refer to EM-26, "Exploded View". D
• Reservoir tank: Refer to CO-14, "Exploded View".
• Radiator core support ornament, radiator core support center and horn: Refer to EXT-18, "Removal and
Installation".
• Hood lock: Refer to DLK-224, "HOOD ASSEMBLY : Exploded View". E
2. Remove condenser pipe assembly. Refer to HA-49, "Removal and Installation".
3. Drain engine coolant from radiator. Refer to CO-8, "Draining".
CAUTION: F
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belts.
4. Disconnect A/T fluid cooler hoses from radiator. (A/T models) G
• Install blind plug to avoid leakage of A/T fluid.
5. Remove radiator hoses (upper and lower) and reservoir tank hose.
CAUTION: H
Be careful not to allow engine coolant to contact drive belts.
6. Remove cooling fan assembly. Refer to CO-17, "Exploded View".
CAUTION: I
Never damage or scratch radiator & condenser assembly core when removing.

7. Rotate two radiator upper mount brackets 90 degrees in direc-

tion as shown in the figure, and remove them. J

1 : Radiator upper mount bracket

A : Turn 90° counterclockwise K

JPBIA0105ZZ
M
8. Remove radiator & condenser assembly as follows:
CAUTION:
Be careful not to damage radiator & condenser assembly core. N
a. Lift up and pull the radiator & condenser assembly (1) forward,
and then remove the mounting rubber (lower) (3) from the radia-
tor core support (2). O

: Vehicle front

JPBIA0106ZZ

Revision: 2008 September CO-15 2008 G35 Sedan

 RADIATOR
< REMOVAL AND INSTALLATION >
b. Remove radiator & condenser assembly (1) from front of radia-
tor core support (2).

: Vehicle front

JPBIA0107ZZ

INSTALLATION
Installation is the reverse order of removal.

Inspection INFOID:0000000001835827

INSPECTION AFTER INSTALLATION

• Check that the reservoir tank cap is tightened.
• Check for leaks of engine coolant using the radiator cap tester adapter (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-8, "Inspection".
• Start and warm up the engine. Visually check that there is no leaks of engine coolant and A/T fluid (A/T mod-
els).

Revision: 2008 September CO-16 2008 G35 Sedan

 COOLING FAN
< REMOVAL AND INSTALLATION >
COOLING FAN
A
Exploded View INFOID:0000000001835828

CO

G
JPBIA0240GB

1. Cooling fan (RH) 2. Cooling fan (LH) 3. Fan shroud

4. Fan motor (LH) 5. Fan motor (RH) 6. Cooling fan control module
H
A. Apply on fan motor shaft
Apply Genuine High Strength Lock-
: ing Sealant or equivalent. I
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000001835829 J

REMOVAL
1. Remove reservoir tank. Refer to CO-14, "Exploded View". K
2. Remove air cleaner case (LH). Refer to EM-26, "Exploded View".
3. Disconnect harness connector from cooling fan control module, and move harness to aside.
4. Remove engine under cover with power tool. L
5. Remove cooling fan assembly from under the vehicle.
CAUTION:
Be careful not to damage or scratch on radiator core. M

INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION: N
Only use genuine parts for cooling fan mounting bolt and observe the specified torque (to prevent
radiator from being damaged).
O
Inspection INFOID:0000000001835830

INSPECTION AFTER REMOVAL

P
Check that fan motors operate normally.
NOTE:
Cooling fans are controlled by cooling fan control module. For details, refer to EC-22, "Component Parts Loca-
tion".
Disassembly and Assembly INFOID:0000000001835831

DISASSEMBLY

Revision: 2008 September CO-17 2008 G35 Sedan

 COOLING FAN
< REMOVAL AND INSTALLATION >
1. Disconnect harness from cooling fan control module.
2. Remove cooling fan control module from cooling fan assembly.
CAUTION:
Handle carefully to avoid dropping and shocks.
3. Remove cooling fan mounting nuts, and then remove the cooling fan (RH and LH).
4. Remove fan motors (RH and LH).
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
CAUTION:
RH and LH cooling fans are different. Be careful not to misassemble them.
• Install each fan in the following position.

Right side : 9 blades

Left side : 11 blades
• Secure the harness tightly to the fan shroud to prevent the fan rotation area from being loose.
Inspection INFOID:0000000001835832

INSPECTION AFTER DISASSEMBLY

Cooling Fan
Inspect cooling fan for crack or unusual bend.
• If anything is found, replace cooling fan.

Revision: 2008 September CO-18 2008 G35 Sedan

 WATER PUMP
< REMOVAL AND INSTALLATION >
WATER PUMP
A
Exploded View INFOID:0000000001835833

CO

G
JPBIA0270GB

1. Timing chain tensioner (primary) 2. Water pump 3. O-ring

4. O-ring
H
Identify with light blue paint mark
A. Identify with yellow paint mark B.
Apply engine coolant
Refer to GI-4, "Components" for symbols in the figure. I

Removal and Installation INFOID:0000000001835834

J
CAUTION:
• When removing water pump assembly, be careful not to get engine coolant on drive belts.
• Water pump cannot be disassembled and should be replaced as a unit.
• After installing water pump, connect hose and clamp securely, then check for leaks using the radia- K
tor cap tester (commercial service tool) and the radiator cap tester adapter (commercial service
tool).
REMOVAL L
1. Remove engine cover. Refer toEM-28, "Exploded View".
2. Release the fuel pressure. Refer to EC-550, "Inspection".
M
3. Disconnect the battery cable from the negative terminal.
4. Remove air duct and air cleaner case assembly (RH and LH). Refer to EM-26, "Exploded View".
5. Remove reservoir tank. Refer to CO-14, "Exploded View". N
6. Separate engine harness removing their brackets from front timing chain case.
7. Remove engine undercover with power tool.
8. Drain engine oil. Refer to LU-9, "Draining". O
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine oil on drive belts. P
9. Drain engine coolant from radiator. Refer to CO-8, "Draining".
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belts.
10. Remove cooling fan assembly. Refer to CO-17, "Exploded View".
11. Remove radiator hose (upper and lower). Refer to CO-14, "Exploded View".
12. Remove front timing chain case. Refer to EM-49, "Exploded View".

Revision: 2008 September CO-19 2008 G35 Sedan

 WATER PUMP
< REMOVAL AND INSTALLATION >
13. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt (1).
b. Loosen upper mounting bolt (2) slowly, and then turn chain ten-
sioner (primary) (3) on the upper mounting bolt so that plunger
(4) is fully expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body
of timing chain tensioner (primary).

JPBIA0085ZZ

c. Remove upper mounting bolt, and then remove timing chain tensioner (primary).

14. Remove water pump as follows:

a. Remove three water pump mounting bolts. Secure a gap between water pump gear and timing chain, by
turning crankshaft counterclockwise until timing chain looseness on water pump sprocket becomes maxi-
mum.

b. Screw M8 bolts (A) [pitch: 1.25 mm (0.0492 in) length: approx.

50 mm (1.97 in)] into water pumps upper and lower mounting
bolt holes until they reach timing chain case. Then, alternately
tighten each bolt for a half turn, and pull out water pump (1).
CAUTION:
• Pull straight out while preventing vane from contacting
socket in installation area.
• Remove water pump without causing sprocket to contact
timing chain.
c. Remove M8 bolts and O-rings from water pump.
CAUTION: JPBIA0111ZZ
Never disassemble water pump.
INSTALLATION
1. Install new O-rings to water pump.
• Apply engine oil to O-ring (1) and engine coolant to O-ring (3)
as shown in the figure.

2 : Water pump
• Locate O-ring with yellow paint mark (A) to front side.
• Locate O-ring with light blue paint mark (B) to rear side.

JPBIA0112ZZ

2. Install water pump.

CAUTION:
Never allow cylinder block to nip O-rings when installing water pump.
• Check timing chain and water pump sprocket are engaged.
• Insert water pump by tightening mounting bolts alternately and evenly.

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

a. Turn crankshaft clockwise so that timing chain on the timing chain tensioner (primary) side is loose.

Revision: 2008 September CO-20 2008 G35 Sedan

 WATER PUMP
< REMOVAL AND INSTALLATION >
b. Pull plunger stopper tab (A) up (or turn lever downward) so as to
remove plunger stopper tab from the ratchet of plunger (D). A
NOTE:
Plunger stopper tab and lever (C) are synchronized.
c. Push plunger into the inside of tensioner body. CO
d. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet.
e. To secure lever, insert stopper pin (E) through hole of lever into C
tensioner body hole (B).
• The lever parts and the tab are synchronized. Therefore, the
plunger will be secured under this condition. JPBIA0118ZZ

NOTE: D
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
f. Install timing chain tensioner (primary).
• Remove dust and foreign material completely from backside of timing chain tensioner (primary) and E
from installation area of rear timing chain case.

g. Remove stopper pin. F

h. Check again that timing chain and water pump sprocket are engaged.
4. Install in the reverse order of removal for remaining parts.
• After starting engine, let idle for three minutes, then rev engine up to 3,000 rpm under no load to G
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.
H
Inspection INFOID:0000000001835835

INSPECTION AFTER REMOVAL

I
• Check for badly rusted or corroded water pump body assembly.
• Check for rough operation due to excessive end play.
• If anything is found, replace water pump.
J

SLC943A

INSPECTION AFTER INSTALLATION M

• Check that the reservoir tank cap is tightened.
• Check for leaks of engine coolant using the radiator cap tester adapter (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-8, "Inspection".
• Start and warm up the engine. Visually check that there is no leaks of engine coolant. N

Revision: 2008 September CO-21 2008 G35 Sedan

 WATER INLET AND THERMOSTAT ASSEMBLY
< REMOVAL AND INSTALLATION >
WATER INLET AND THERMOSTAT ASSEMBLY
Exploded View INFOID:0000000001835836

JPBIA1466GB

1. Gasket 2. Water inlet and thermostat assembly

Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000001835837

REMOVAL
1. Remove engine cover. Refer to EM-28, "Exploded View".
2. Remove air duct and air cleaner case assembly (LH). Refer to EM-26, "Exploded View".
3. Remove reservoir tank. Refer to CO-14, "Exploded View".
4. Remove oil cooler water pipe mounting bolt, and move aside water pipe. (AWD models) Refer to LU-14,
"AWD : Exploded View".
5. Remove engine undercover with power tool.
6. Drain engine coolant from radiator drain plug at the bottom of radiator. Refer to CO-8, "Draining".
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belts.
7. Disconnect radiator hose (lower).
8. Disconnect intake valve timing control valve harness connector (LH), and remove intake valve timing con-
trol solenoid.
9. Remove water inlet and thermostat assembly (1).
CAUTION:
Never disassemble water inlet and thermostat assembly.
Replace them as a unit, if necessary.

A : Do not loosen these screw.

JPBIA0261ZZ

INSTALLATION
Note the following, and install in the reverse order of removal.

Revision: 2008 September CO-22 2008 G35 Sedan

 WATER INLET AND THERMOSTAT ASSEMBLY
< REMOVAL AND INSTALLATION >
• Be careful not to spill engine coolant over engine room. Use rag to absorb engine coolant.
A
Inspection INFOID:0000000001835838

INSPECTION AFTER REMOVAL

CO
1. Check valve seating condition at ordinary room temperatures. It should seat tightly.
2. Check valve operation.
C
Thermostat (Standard) : Refer to CO-26, "Thermostat".
• If the malfunctioning condition, when valve seating at ordinary
room temperature, or measured values are out of the standard, D
replace water inlet and thermostat assembly.

SLC949A

INSPECTION AFTER INSTALLATION F

• Check that the reservoir tank cap is tightened.
• Check for leaks of engine coolant using the radiator cap tester adapte (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-8, "Inspection". G
• Start and warm up the engine. Visually check that there is no leaks of engine coolant.

Revision: 2008 September CO-23 2008 G35 Sedan

 WATER OUTLET AND WATER PIPING
< REMOVAL AND INSTALLATION >
WATER OUTLET AND WATER PIPING
Exploded View INFOID:0000000001835839

JPBIA0247GB

1. Clamp 2. Water hose 3. Harness bracket

4. Water outlet (rear) 5. Heater hose 6. Gasket
7. Washer 8. Engine coolant temperature sensor 9. O-ring
10. Water outlet pipe 11. Water outlet (front) 12. Clamp
13. Radiator hose (upper) 14. Gasket 15. Water pipe
16. Clamp 17. Water hose 18. Water hose
19. Gasket 20. Heater pipe 21. Clamp
22. Water hose 23. Clamp 24. Heater hose
25. Water bypass pipe 26. O-ring 27. Heater hose
A. To EVAP piping B. To heater core C. To radiator
D. To oil cooler E. To electric throttle control actuator F. AWD models
Refer to GI-4, "Components" for symbols in the figure.

Removal and Installation INFOID:0000000001835840

REMOVAL
1. Remove engine cover. Refer to EM-28, "Exploded View".
2. Remove reservoir tank. Refer to CO-14, "Exploded View".
3. Remove oil level gauge and guide. Refer to EM-42, "Exploded View (2WD)" or EM-43, "Exploded View
(AWD)".
4. Remove air duct and air cleaner case assembly (RH and LH). Refer to EM-26, "Exploded View".
5. Remove engine undercover with power tool.

Revision: 2008 September CO-24 2008 G35 Sedan

 WATER OUTLET AND WATER PIPING
< REMOVAL AND INSTALLATION >
6. Drain engine coolant from radiator drain plug at the bottom of radiator. Refer to CO-8, "Draining".
CAUTION: A
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belts.
7. Remove radiator hose (upper) and heater hose. CO
8. Remove the following parts, when remove water outlet (rear).
• A/T fluid charging pipe (A/T models): Refer to TM-278, "2WD : Removal and Installation" (2WD models)
or TM-280, "AWD : Removal and Installation" (4WD models).
C
• Intake manifold collector: Refer to EM-28, "Exploded View".
9. Separate engine harness removing their bracket from water outlet (rear).
10. Remove engine coolant temperature sensor as necessary. D
CAUTION:
Be careful not to damage engine coolant temperature sensor.
11. Remove heater pipe, water bypass pipe and water outlet pipe.
E
INSTALLATION
Note the following, and install in the reverse order of removal.
• Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge. F
• When inserting water outlet pipe and water bypass pipe into water outlet, apply neutral detergent to O-ring.
CAUTION:
Never allow water outlet (rear) to nip O-rings when installing water outlet pipe and water bypass pipe.
G
Inspection INFOID:0000000001835841

INSPECTION AFTER INSTALLATION H

• Check that the reservoir tank cap is tightened.
• Check for leaks of engine coolant using the radiator cap tester adapte (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to CO-8, "Inspection".
• Start and warm up the engine. Visually check that there is no leaks of engine coolant. I

Revision: 2008 September CO-25 2008 G35 Sedan

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Periodical Maintenance Specification INFOID:0000000001835842

ENGINE COOLANT CAPACITY (APPROXIMATE)

Unit: (US qt, Imp qt)

With oil cooler A/T models 9.0 (9-1/2, 7-7/8)

models M/T models 9.1 (9-5/8, 8)
Engine coolant capacity [With reservoir tank (“MAX” level)]
Without oil cooler A/T models 8.5 (9, 7-1/2)
models M/T models 8.6 (9-1/8, 7-5/8)
Reservoir tank engine coolant capacity (At “MAX” level) 0.8 (7/8, 3/4)

Radiator INFOID:0000000001835843

Unit: kPa (kg/cm2, psi)

Standard 122.3 - 151.7 (1.2 - 1.5, 18 - 22)

Cap relief pressure
Limit 107 (1.1, 16)
Leakage testing pressure 157 (1.6, 23)

Thermostat INFOID:0000000001835844

Thermostat Standard
Valve opening temperature 82°C (180°F)
Maximum valve lift 9.0 mm/95°C (0.354 in/203°F)
Valve closing temperature 77°C (171°F)

Revision: 2008 September CO-26 2008 G35 Sedan