ENGINE COOLING SYSTEM

B ENGINE

ENGINE COOLING SYSTEM

SECTION CO CO

E
CONTENTS
PRECAUTIONS .......................................................... 2 RADIATOR (ALUMINUM TYPE) ............................... 14 F
Precautions for Battery Service ................................ 2 Disassembly and Assembly .................................... 14
Precautions for Supplemental Restraint System PREPARATION ................................................... 14
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- DISASSEMBLY ................................................... 14 G
SIONER” .................................................................. 2 ASSEMBLY ......................................................... 15
Precautions for Liquid Gasket .................................. 2 INSPECTION ...................................................... 17
REMOVAL OF LIQUID GASKET SEALING .......... 2 COOLINGFAN ........................................................... 18
H
LIQUID GASKET APPLICATION PROCEDURE..... 2 Removal and Installation ........................................ 18
PREPARATION ........................................................... 4 REMOVAL ........................................................... 18
Special Service Tools ............................................... 4 INSTALLATION ................................................... 18
Commercial Service Tools ........................................ 4 Disassembly and Assembly .................................... 18 I
OVERHEATING CAUSE ANALYSIS .......................... 5 DISASSEMBLY ................................................... 18
Troubleshooting Chart .............................................. 5 ASSEMBLY ......................................................... 18
COOLING SYSTEM .................................................... 7 WATER PUMP .......................................................... 19 J
Cooling Circuit .......................................................... 7 Removal and Installation ........................................ 19
ENGINE COOLANT .................................................... 8 REMOVAL ........................................................... 19
Inspection ................................................................. 8 INSPECTION AFTER REMOVAL ....................... 21
K
LEVEL CHECK ..................................................... 8 INSTALLATION ................................................... 21
LEAK CHECK ....................................................... 8 THERMOSTAT AND THERMOSTAT HOUSING ...... 23
Changing Engine Coolant ........................................ 8 Removal and Installation ........................................ 23
DRAINING ENGINE COOLANT ........................... 8 REMOVAL ........................................................... 23 L
REFILLING ENGINE COOLANT .......................... 9 INSPECTION AFTER REMOVAL ....................... 23
FLUSHING COOLING SYSTEM ......................... 10 INSTALLATION ................................................... 23
RADIATOR .................................................................11 WATER OUTLET AND WATER PIPING ................... 24 M
Removal and Installation .........................................11 Removal and Installation ........................................ 24
REMOVAL ............................................................11 REMOVAL ........................................................... 24
INSTALLATION ................................................... 13 INSTALLATION ................................................... 24
Checking Radiator Cap .......................................... 13 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 25
Checking Radiator .................................................. 13 Engine Coolant Capacity (Approximate) ................ 25
Thermostat ............................................................. 25
Radiator .................................................................. 25
Tightening Torque ................................................... 25

Revision; 2004 April CO-1 2003 350Z

 PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Battery Service ABS003MG

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” ABS002CR

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
● 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.
● 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.
● 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 ABS000QL

REMOVAL OF LIQUID GASKET SEALING

● After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
● In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the RTV Silicone Sealant is
applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur- PBIC0002E

faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket tube to the tube presser.
● Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-47, "RECOMMENDED CHEMICAL PRODUCTS AND PBIC0003E
SEALANTS" .

Revision; 2004 April CO-2 2003 350Z

 PRECAUTIONS

4. Apply the liquid gasket without breaks to the specified location

with the specified dimensions. A
● If there is a groove for the liquid gasket application, apply the liq-
uid gasket to the groove.
CO

EMA0622D

D
● As for the bolt holes, normally apply the liquid gasket inside the
holes. Occasionally, it should be applied outside the holes. Make
sure to read the text of this manual. E
● Within five minutes of gasket application, install the mating com-
ponent.
● If the liquid gasket protrudes, wipe it off immediately. F
● Do not retighten after the installation.
● Wait 30 minutes or more after installation before filling the
engine with oil and coolant. G
CAUTION: SEM159F
If there are specific instructions in this manual, observe them.
H

Revision; 2004 April CO-3 2003 350Z

 PREPARATION

PREPARATION PFP:00002

Special Service Tools ABS000QM

The actual shapes of Kent-Moore tools may from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name

WS39930000 Pressing the tube of liquid gasket

( – )
Tube pressure

S-NT052

EG17650301 Adapting radiator cap tester to radiator cap

(J33984-A) and radiator filler neck
Radiator cap tester adapter a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

S-NT564

KV99103510 Installing radiator upper and lower tanks

( – )
Radiator plate pliers A

S-NT224

KV99103520 Removing radiator upper and lower tanks

( – )
Radiator plate pliers B

S-NT225

Commercial Service Tools ABS000QN

Tool name Description

Power tool Loosening bolts and nuts

PBIC0190E

Revision; 2004 April CO-4 2003 350Z

 OVERHEATING CAUSE ANALYSIS

OVERHEATING CAUSE ANALYSIS PFP:00012

A
Troubleshooting Chart ABS000QO

Symptom Check items

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

Revision; 2004 April CO-5 2003 350Z

 OVERHEATING CAUSE ANALYSIS

Symptom Check items

High engine rpm under no
load
Driving in low gear for
Abusive driving
extended time
Driving at extremely high
speed
— Overload on engine
Powertrain system mal-
function
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
Blocked or restricted air paper clogging —
flow
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp

Revision; 2004 April CO-6 2003 350Z

 COOLING SYSTEM

COOLING SYSTEM PFP:21020

A
Cooling Circuit ABS000QP

CO

PBIC0836E

PBIC0847E

Revision; 2004 April CO-7 2003 350Z

 ENGINE COOLANT

ENGINE COOLANT PFP:KQ100

Inspection ABS000QQ

LEVEL CHECK
● Check if the reservoir tank engine coolant level is within the MIN
to MAX range when the engine is cool.
● Adjust the coolant level as necessary.

SMA412B

LEAK CHECK
● To check for leaks, apply pressure to the cooling system with the
tester.
Testing pressure : 157 kPa (1.6 kg/cm2 , 23 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 test pressure than specified may cause radiator dam-
age. SLC756A

NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
Changing Engine Coolant ABS000QR

WARNING:
● To avoid being scalded, never change the engine coolant when the engine is hot.
● 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 turn the cap all the way.
● Be careful not to allow engine coolant to contact drive belts.
DRAINING ENGINE COOLANT
1. Remove engine undercover using power tools.
2. Open radiator drain plug at the bottom of radiator, and remove
radiator cap.
When draining all the engine coolant in the system, also perform
the following steps.
3. Remove the reservoir tank, drain the engine coolant and clean
the tank before installing.

PBIC0893E

Revision; 2004 April CO-8 2003 350Z

 ENGINE COOLANT

4. Drain engine coolant from both sides of cylinder block at B and

C in the figure and cylinder block front at A in the figure when A
draining all the engine coolant in the system.
5. Check drained engine coolant for contaminants such as rust,
corrosion or discoloration. CO
If contaminated, flush the engine cooling system. Refer to CO-
10, "FLUSHING COOLING SYSTEM" .
C

G
KBIA1021E

REFILLING ENGINE COOLANT

1. Install reservoir tank if removed, and radiator drain plug. H
2. Close and tighten cylinder block drain plugs securely if removed.
● Apply sealant to the threads of the cylinder block drain plugs.

● Use Genuine Thread Sealant or equivalent. Refer to MA-11, "RECOMMENDED FLUIDS AND I
LUBRICANTS".
Radiator drain plug: J
: 0.78 - 1.6 N·m (0.08 - 0.15 kg-m, 7 - 13 in-lb)
Cylinder block drain plug (LH):
: 17.6 - 21.6 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb) K
Cylinder block drain plug (RH):
: 17.6 - 21.6 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb) L
Cylinder block drain plug (Front side):
: 7.8 - 11.8 N.m (0.8 - 1.2 Kg-m, 69 - 104 in-lb)
M
3. Remove air relief plug on heater hose.

PBIC1050E

Revision; 2004 April CO-9 2003 350Z

 ENGINE COOLANT

4. Fill radiator and reservoir tank to specified level.

● Pour engine coolant through coolant filler neck slowly of
less than 2 (2-1/8US qt,1-3/4 lmp qt) a minute to allow
air in system to escape.
● Use genuine Nissan Anti-freeze Coolant or equivalent
mixed with water (distilled or demineralized. Refer to MA-
11, "RECOMMENDED FLUIDS AND LUBRICANTS".
Engine coolant capacity
(with reservoir tank at MAX level)
: Approximately 8.7 (9-1/4 US qt, 7-5/8 lmp qt) SMA182B

Reservoir tank capacity (at MAX level)

: 0.8 (7/8 US qt, 3/4 lmp qt)
● When engine coolant overflows air relief hole on heater hose,
install air relief plug with new O-ring.
Air relief plug:
: 0.78 - 1.6 N·m (0.08 - 0.15 kg-m, 7 - 13 ft-lb)
5. Warm up engine to normal operating temperature with radiator
cap installed.
SMA412B
6. Run engine at 3,000 rpm for 10 seconds and return to idle
speed.
● Repeat two or three times.

7. Stop engine and cool down to less than approximately 50°C (122°F).
● Cool down using a fan to reduce the time.

● If necessary, refill radiator up to filler neck with engine coolant.

8. Refill reservoir tank to MAX level line with engine coolant.

9. Repeat steps 4 through 7 two or more times with radiator cap installed until engine coolant level no longer
drops.
10. Check cooling system for leaks with engine running.
11. Warm up engine, and check for sound of engine coolant flow while running engine from idle up to 3,000 r
pm with heater temperature controller set at several position between COOL and WARM.
● Sound may be noticeable at heater unit.
12. Repeat step 11 three times.
13. If sound is heard, bleed air from cooling system by repeating step 4 through 7 until engine coolant level no
longer drops.
● Clean excess engine coolant from engine.
FLUSHING COOLING SYSTEM
1. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and
reservoir tank with water and reinstall radiator cap.
2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down.
5. Drain the water from the system. Refer to CO-8, "DRAINING ENGINE COOLANT" .
6. Repeat steps 1 through 5 until clear water begins to drain from the radiator.

Revision; 2004 April CO-10 2003 350Z

 RADIATOR

RADIATOR PFP:21400
A
Removal and Installation ABS000QS

CO

PBIC1670E
K
1. Radiator 2. Bracket 3. Mounting rubber
4. Radiator cap 5. Radiator hose (lower) 6. O-ring
7. A/T oil cooler hose 8. Radiator hose (upper) 9. Reservoir tank hose L
10. Cap 11. Reservoir tank 12. Drain plug
13. Radiator cooling fan assembly 14. Cover

WARNING: M
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
engine coolant escaping from the radiator.
REMOVAL
1. Remove undercover using power tool.
2. Drain engine coolant from the radiator. Refer to CO-8, "Changing Engine Coolant" .
CAUTION:
Perform when the engine is cold.
3. Remove air duct and air cleaner case assembly. Refer to EM-15, "Removal and Installation" .
4. Remove reservoir tank and bracket.
5. Disconnect A/T oil cooler hoses.
● Install blind plug to avoid leakage of A/T fluid.

6. Disconnect radiator upper and lower hoses.

7. Remove radiator cooling fan assembly.

Revision; 2004 April CO-11 2003 350Z

 RADIATOR

8. Rotate two radiator upper mount brackets 90 degrees in the

direction shown in the figure, and remove them.
9. Remove bracket mounting bolt for anchoring A/C piping from
vehicle left side, so that A/C piping can be moved.

PBIC1052E

10. Remove cover, and then two A/C condenser mounting bolts
located in upper part of radiator.

PBIC1053E

11. Lift the A/C condenser up approximately 2 cm (0.79 in).

Remove the radiator mounting brackets.
CAUTION:
To avoid putting a load on the A/C piping, be careful not to
lift too much.
12. Lift up and remove the radiator.
CAUTION:
● Do not damage or scratch A/C condenser and radiator
core when removing.
● After removing the radiator, fix the A/C condenser on the
vehicle side with a rope or similar means.This is to pre-
vent a load being applied to the A/C piping.
PBIC1054E

Revision; 2004 April CO-12 2003 350Z

 RADIATOR

INSTALLATION
● Install in the reverse order of removal. A

Checking Radiator Cap ABS008HT

1. Pull the negative-pressure valve to open it and check that it closes completely when released. CO
● Check that there is no dirt or damage on the valve seat of the
radiator cap negative-pressure valve.
● Check that there are no unusualness in the opening and clos- C
ing conditions of the negative-pressure valve.

E
SMA967B

2. Check radiator cap relief pressure. F

Standard:
78 - 98 kPa (0.8 - 1.0 kg/cm2 , 11 - 14 psi)
G
Limit:
59 kPa (0.6 kg/cm2 , 9 psi)
● When connecting the radiator cap to the radiator cap tester H
adapter (special service tool) and radiator cap tester, apply
engine coolant to the cap seal surface.
● Replace the radiator cap if there is an unusualness in the neg- SLC755A I
ative-pressure valve, or if the open-valve pressure is outside
of the limit.
Checking Radiator ABS008HU
J

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

● Be careful not to bend or damage the radiator fins. K
● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator
shroud and horns. Then tape the harness and electrical connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically downward. L
2. Apply water again to all radiator core surface once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically downward. M
2
● Use compressed air lower than 490 kPa (5 kg/cm , 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.

Revision; 2004 April CO-13 2003 350Z

 RADIATOR (ALUMINUM TYPE)

RADIATOR (ALUMINUM TYPE) PFP:21460

Disassembly and Assembly ABS000QT

SLC882AB

PREPARATION
1. Attach the spacer to the tip of the radiator plate pliers A (special
service tool).
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in)
wide x 8.5 mm (0.335 in) long.
2. Make sure that when radiator plate pliers A (special service tool)
are closed dimension H′′ is approx. 7.6 mm (0.299 in).
3. Adjust dimension H′′ with the spacer, if necessary.

SLC655CB

DISASSEMBLY
1. Remove upper and lower tanks with radiator plate pliers B (spe-
cial service tool).

SLC903-A

Revision; 2004 April CO-14 2003 350Z

 RADIATOR (ALUMINUM TYPE)

● Grip the crimped edge and bend it upwards so that radiator

plate pliers B (special service tool) slips off. A
Do not bend excessively.

CO

SLC893

D
● In areas where radiator plate pliers B (special service tool) can-
not be used, use a screwdriver to bend the edge up.
Be careful not to damage tank.
E
2. Remove sealing rubbers.

G
SLC930

3. Make sure the edge stands straight up. H

4. Remove oil cooler from tank. (A/T model)

SLC931 K
ASSEMBLY
1. Install oil cooler. (A/T model)
Pay attention to direction of conical washer. L

SLC894

Revision; 2004 April CO-15 2003 350Z

 RADIATOR (ALUMINUM TYPE)

2. Clean contact portion of tank.

SLC932

3. Install sealing rubber.

Push it in with fingers.
Be careful not to twist sealing rubber.

SLC917A

4. Caulk tank in specified sequence with radiator plate pliers A

(special service tool).

SLC904-A

SLC896

● Use pliers in the locations where radiator plate pliers A (special

service tool) cannot be used.

SLC897

Revision; 2004 April CO-16 2003 350Z

 RADIATOR (ALUMINUM TYPE)

5. Make sure that the rim is completely crimped down. A

Standard height “H” : 8.0 - 8.4 mm (0.315 - 0.331 in)
6. Confirm that there is no leakage.
CO
Refer to CO-17, "INSPECTION" .

SLC554A
D
INSPECTION
1. Apply pressure with radiator cap tester adapter (special service
tool) and radiator cap tester. E
Specified pres- : 157 kPa (1.6 kg/cm2 , 23 psi)
sure value
F
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
CAUTION: G
Attach a hose to the oil cooler to seal its inlet and outlet.
(A/T models) SLC933-A

H
2. Check for leakage by soaking radiator in water container with
the testing pressure applied.
I

K
SLC934

Revision; 2004 April CO-17 2003 350Z

 COOLINGFAN

COOLINGFAN PFP:21060

Removal and Installation ABS008I4

PBIC1056E

1. Cooling fan 2. Fan shroud 3. Fan motor

REMOVAL
1. Drain engine coolant from the radiator. Refer to CO-8, "Changing Engine Coolant" .
CAUTION:
Perform when the engine is cold.
2. Remove air duct (inlet) and air cleaner case assembly. Refer to EM-15, "AIR CLEANER AND AIR DUCT"
.
3. Disconnect radiator upper hose.
4. Disconnect fan motor connectors.
5. Remove radiator cooling fan assembly.
INSTALLATION
Install in the reverse order of removal.
● Cooling fan is controlled by ECM. For details, refer to EC-475, "DTC P1217 ENGINE OVER TEMPERA-
TURE" .
Disassembly and Assembly ABS008I5

DISASSEMBLY
1. Remove fans from fan motors.
2. Remove fan motors from fan shroud.
ASSEMBLY
Install in the reverse order of disassembly.

Revision; 2004 April CO-18 2003 350Z

 WATER PUMP

WATER PUMP PFP:21020

A
Removal and Installation ABS000QW

CO

PBIC1288E
G

1. Chain tensioner 2. Chain tensioner cover 3. Water pump cover

4. Water pump 5. O - rings 6. Drain plug H
CAUTION:
● When removing water pump assembly, be careful not to get engine coolant on drive belt.
● Water pump cannot be disassembled and should be replaced as a unit. I
● After installing water pump, connect hose and clamp securely, then check for leaks using radiator
cap tester.
J
REMOVAL
1. Remove undercover using power tools.
2. Remove drive belts. Refer to EM-14, "Removal and Installation"
K
.
3. Drain engine coolant from radiator. Refer to CO-8, "Changing
Engine Coolant" .
L
CAUTION:
Perform when the engine is cold.
4. Remove water drain plug on water pump side of cylinder block.
M
5. Remove chain tensioner cover and water pump cover.
6. Remove the chain tensioner assembly with the following proce- PBIC0846E

dure.
a. Pull the lever down and release the plunger stopper tab.
● Plunger stopper tab can be pushed up to release (coaxial structure with lever).

b. Insert the stopper pin into the tensioner body hole to hold the
lever and keep the stopper tab released.
NOTE:
An allen wrench [2.5 mm (0.098 in)] is used for a stopper pin as
an example.
c. Insert the plunger into the tensioner body by pressing the timing
chain slack guide.
d. Keep the slack guide pressed and hold the plunger in by push-
ing the stopper pin deeper through the lever and into the ten-
sioner body hole.
SLC444B

Revision; 2004 April CO-19 2003 350Z

 WATER PUMP

e. Turn crankshaft pulley approximately 20° clockwise so that the

timing chain on the chain tensioner side is loose.

PBIC0848E

7. Remove chain tensioner.

CAUTION:
Be careful not to drop mounting bolts inside chain case.

PBIC0849E

8. Remove the 3 water pump fixing 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.

PBIC1193E

9. Screw M8 bolts [pitch: 1.25 mm (0.049 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.
● Pull straight out while preventing vane from contacting socket in
installation area.
● Remove water pump without causing sprocket to contact timing
chain.
10. Remove M8 bolts and O-rings from water pump.
JLC357B

Revision; 2004 April CO-20 2003 350Z

 WATER PUMP

INSPECTION AFTER REMOVAL

1. Check for badly rusted or corroded water pump body assembly. A
2. Check for rough operation due to excessive end play.

CO

SLC943A
D

INSTALLATION
1. Install new O-rings to water pump.
E
2. Apply engine oil and engine coolant to the O-rings as shown.
● Locate the O-ring with white paint mark to engine front side.

H
PBIC1397E

3. Install the water pump. I

● Do not allow cylinder block to nip the O-rings when
installing the water pump.
● Check that timing chain and water pump sprocket are J
engaged.
● Insert water pump by tightening mounting bolts alternately
and evenly. K

4. Remove dust and foreign material completely from backside of

chain tensioner and from installation area of rear timing chain PBIC1058E L
case.
5. Turn the crankshaft pulley clockwise so that the timing chain on the timing chain tensioner side is loose.
● When installing the timing chain tensioner, engine oil should be applied to the oil hole and ten- M
sioner.
6. Install the timing chain tensioner.
7. Remove the stopper pin.

SLC448B

Revision; 2004 April CO-21 2003 350Z

 WATER PUMP

8. Install chain tensioner cover and water pump cover.

a. Before installing, remove all traces of liquid gasket from mating
surface of water pump cover and chain tensioner cover using a
scraper.
Also remove traces of liquid gasket from the mating surface of
the front cover.

SLC446B

b. Apply a continuous bead of liquid gasket to mating surface of

chain tensioner cover and water pump cover.
Use Genuine RTV Silicon Sealant or equivalent. Refer to GI-
47, "RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS" .
9. Install water drain plug on water pump side of cylinder block.
10. Installation is 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 purge air from the
high-pressure chamber of the chain tensioner. The engine
may produce a rattling noise. This indicates that air still SLC447B

remains in the chamber and is not a matter of concern.

Revision; 2004 April CO-22 2003 350Z

 THERMOSTAT AND THERMOSTAT HOUSING

THERMOSTAT AND THERMOSTAT HOUSING PFP:21200

A
Removal and Installation ABS000QX

CO

PBIC1669E
G

REMOVAL
1. Remove undercover using power tools. H
2. Drain engine coolant from radiator. Refer to CO-8, "Changing Engine Coolant" .
3. Remove air duct and air cleaner case assembly. Refer to EM-15, "Removal and Installation" .
4. Remove water drain plug on water pump side of the engine. I
5. Remove radiator lower hose from thermostat and thermostat housing.
6. Remove oil cooler water hose from thermostat and thermostat housing.
J
7. Remove thermostat and thermostat housing.
● Do not disassemble thermostat and thermostat housing.
Replace them as a unit, if necessary.
K

M
PBIC1398E

INSPECTION AFTER REMOVAL

1. Check valve seating condition at ordinary room temperatures. It should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Thermostat Standard
Valve opening temperature 76.5°C (170°F)
Valve lift 8.6 mm / 90°C (0.339 in / 194°F)
3. Then check if valve closes at 5°C (9°F) below valve opening
temperature.

SLC949A

INSTALLATION
Install in the reverse order of removal.

Revision; 2004 April CO-23 2003 350Z

 WATER OUTLET AND WATER PIPING

WATER OUTLET AND WATER PIPING PFP:11060

Removal and Installation ABS000QY

PBIC1060E

1. Harness bracket 2. Water hose 3. Water bypass hose

4. Engine coolant temperature sensor 5. Gasket 6. Water outlet
7. Heater hose 8. Water pipe 9. Radiator upper hose
10. Heater pipe

REMOVAL
1. Remove undercover using power tool.
2. Drain engine coolant from drain plugs on radiator and both sides of cylinder block. Refer to CO-8, "Chang-
ing Engine Coolant" .
3. Remove engine cover using power tool.
4. Remove air duct and air cleaner case assembly. Refer to EM-15, "Removal and Installation" .
5. Remove radiator upper hose and heater hose.
INSTALLATION
Install in the reverse order of removal.
● Securely insert each hose, and install a clamp at a position where it does not interfere with the pipe bulge.
● When inserting a water pipe into water outlet, apply neutral detergent to O-ring.

Revision; 2004 April CO-24 2003 350Z

 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00100

A
Engine Coolant Capacity (Approximate) ABS000QZ

Engine coolant capacity (With reservoir tank at MAX level) 8.7 (9-1/4 US qt, 7- 5/8 lmp qt)
CO
Reservoir tank engine coolant capacity (at MAX level) 0.8 (7/8 US qt, 3/4 lmp qt)

Thermostat ABS000R0

C
Valve opening temperature 76.5°C (170°F)
Valve lift 8.6 mm / 90°C (0.339 in / 194°F)

Radiator ABS000R1
D
Unit: kPa (kg/cm2 , psi)
Standard 78 - 98 (0.8 - 1.0, 11 - 14) E
Cap relief pressure
Limit 59 (0.6, 9)
Leakage test pressure 157 (1.6, 23)
F
Tightening Torque ABS000R2

Unit: N·m (kg-m, ft-lb)

Unit: N·m (kg-m, in-lb)*
Cylinder block drain plug (LH) 17.6 - 21.6 (1.8 - 2.2, 13 - 15) G
Cylinder block drain plug (RH) 17.6 - 21.6 (1.8 - 2.2, 13 - 15)
Cylinder block drain plug (Front side) 7.8 - 11.8 (0.8 - 1.2, 69 - 104)*
H
Air relief plug 0.78 - 1.6 (0.08 - 0.15, 7 - 13)*
Radiator drain plug 0.78 - 1.6 (0.08 - 0.15, 7 - 13)*
Fan 2.9 - 3.9 (0.3 - 0.4, 26 - 34)* I
Radiator cooling fan assembly 3.8 - 4.5 (0.39 - 0.45, 34 - 39)*
Fan motor 3.9 - 4.9 (0.4 - 0.5, 35 - 43)*
J
Water pump 8.4 - 10.8 (0.9 - 1.1, 75 - 95)*
Water pump cover 9.8 - 12.8 (1.0 - 1.3, 87 - 113)
Chain tensioner cover 9.8 - 12.8 (1.0 - 1.3, 87 - 113) K
Chain tensioner 6.9 - 9.3 (0.70 - 0.94, 61 - 82)*
Water outlet 21.6 - 27.4 (2.2 - 2.7, 16 - 20)
L
Thermostat and thermostat housing 8.4 - 10.8 (0.9 - 1.1, 75 - 95)*
Engine coolant temperature sensor 19.6 - 29.4 (2.0 - 2.9, 15 - 21)

Revision; 2004 April CO-25 2003 350Z

 SERVICE DATA AND SPECIFICATIONS (SDS)

Revision; 2004 April CO-26 2003 350Z