Nissan Forklift Internal Combustion F03 series Service Repair Manual

COOLING SYSTEM COOLING SYSTEM -p Engine- (CO) CONTENTS SERVICE DATA AND SPECiFiCATIONS CO-2 TROUBLE DIAGNOSES AND CORRECTIONS CO-2 COOLING SySTEM CO-4 WATER PUMP CO-4 THERMOSTAT CO-4 RADIATOR CO-5

Service Data and Specifications - Trouble Diagnoses and Corrections- COOLING SYSTEM SERVICE DATA AND SPECIFICATIONS Valve opening temperature 0C (OF) 82 (180) Max. valve lift mm/oC (in/oF) 10/95 (0.39/203) GENERAL SPECIFICATIONS Cooling method Water cooling, forced circulation Water pump type Centrifugal Thermostat type Wax-pellet Radiator type Plate and fin Cooling fan Fan dia. x No. of blades 440 (17.32) x 6 mm (in) Coolant capacity 18.0 (19,15-7/8) Q (US qt, Imp qtl Thermostat Radiator Cap relief pressure Leakage test pressure TIGHTENING TORQUE Unit: kPa (bar, kg/cm 2 , psi) 88 (0.88, 0.9, 13) 157 (1.57, 1.6, 23) INSPECTION AND ADJUSTMENT Water pump Fan belt deflection [Applied force 98 N (10 kg, 22 Ib)] mm (in) 8-12 (0.31 - 0.47) Unit N'm kg-m ft-Ib Water pump bolt and 25- 34 2.5 - 3.5 18- 25 nut Water pump pulley bolt 6-9 0.6-0.9 4.3 - 6,5 Thermostat housing 10 - 12 1.0 - 1.2 7-9 Water outlet bolt 10 - 12 1.0 - 1.2 7-9 TROUBLE DIAGNOSES AND CORRECTIONS Condition Water leakage CO-2 Probable cause Damaged radiator seams. Leaks from heater connections or plugs. Leak from water pump shaft seal. Leak from water temperature gauge. Leaks from gaskets or small cracks. Loose joints. Damaged cylinder head gasket. Cracked cylinder block. Cracked cylinder head. Loose cylinder head bolts. Corrective action Repair. Repair. Replace as pump assembly. Tighten. Tighten or use Nissan Cooling System Sealer or equivalent. Tighten. Replace. Check engine oil for contamination and refill as necessary. Replace. Check engine oil in crankcase for mixing with water by pulling oil level gauge. Replace. Replace cylinder head gasket.

COOLING SYSTEM- Trouble Diagnoses and Corrections Condition Probable cause Corrective action Poor circulation Restriction in system. Check hoses for crimps, and clear the system of rust and sludge by flushing radiator. Insufficient coolant. Replenish. Inoperative water pump. Replace. Loose fan belt. Adjust. Inoperative thermostat. Replace. Corrosion Excessive impurity in water. Use soft, clean water. (rain water is satis- factory). Infrequent flushing and draining of system. Cooling system should be drained and flush- ed thoroughly at least twice a year. Perma- nent antifreeze (Ethylene glycol base) can be used throughout the seasons of a year. Overheating Malfunctioning thermostat, radiator cap and Replace. fan coupling. Radiator fm choked with mud, chaff, etc. Clean out air passage thoroughly by using air pressure from engine side of radiator. Incorrect ignition and valve timing. Adjust. Dirty oil and sludge in engine. Refill. Inoperative water pump. Replace. Loose fan belt. Adjust. Restricted radiator. Flush radiator. Inaccurate temperature gauge. Replace. Impurity in water. Use soft, clean water. Overcooling Malfunctioning thermostat. Replace. Inaccurate temperature gauge. Replace. Noise Squeak at water pump mechanical seal. Replace pump assembly. Damaged or worn water pump bearing. Replace pump assembly. CO-3

Cooling System - COOLING SYSTEM COOLING SYSTEM WATER PUMP REMOVAL 1. Open radiator drain cock and allow coolant to drain into a suitable container. WARNING: To avoid the danger of being scald- ed, never attempt to drain the cool. ant when the engine is hot. 2. Remove radiator shroud. 3. Loosen two fan belts. 4. Remove fan and water pump pulley. 5. Remove water pump with gasket. INSPECTION 1. Inspect water pump body and vane for rust or corrosion. CO-4 2. Check water pump bearing for excessive and play or rough operation. SLC071 INSTALLATION 1. Install water pump in reverse order of removal. Always use new gasket. 2. Adjust fan belt tension. Fan belt deflection: 8- 12 mm (0.31 - 0.47 in) Pushing force: 98 N (10 kg, 22 Ib) 3. Fill radiator with coolant. For details, refer to Changing Engine Coolant in Section MA. THERMOSTAT ~ ! ~ w.. ,,:,::::~ Th~mt'~!1 ~._Ga.S.).k:et ~ 0; 'riNJ Thermostat housing Fan drive bearing assembly FC0006 REMOVAL 1. Drain a small amount of coolant partially and disconnect radiator upper hose at water outlet. WARNING: To avoid the danger of being scald. ed, never attempt to drain the coolant when the engine is hot. 2. Remove water outlet and then remove thermostat. INSPECTION Inspect thermostat for the follow- ing and replace if necessary. 1. Valve seating condition at ordi- nary temperature. It should seat tightly. 2. Valve opening temperature and maximum valve lift (Refer to S.D.S.). 3. Then check if valve closes at 5°C (9°F) below valve opening temperature. It is necessary to check a new thermostat before installing it in engine.

COOLING SYSTEM-CoolingSystem INSTALLATION 1. Position thennostat on thennostat housing. 2. Install water outlet with new gasket. 3. Connect radiator upper hose and fIll radiator with coolant. 4. Run engine for a few minutes, and check for leaks. RADIATOR INSPECTION Checking radiator cap Using cap tester, check the radiator cap relief pressure. If the pressure gauge drops rapidly and excessively, replace the radiator cap. SLC081 Checking cooling system for leaks Attach pressure tester to the radiator filler neck, then pump tester to the specifIed pressure. Check for drop in pressure. Test pressure: 157 kPa (1.57 bar, 1.6 kg/cm 2 , ~3 psi) If the pressure drops, check for leaks from hoses, radiator, or water pump. If no external leaks are found, check block and head. REMOVAL AND INSTALLATION 1. Open radiator drain cock and allow to drain into a suitable container. WARNING: To avoid the danger of being scald- ed, never attempt to drain the coolant when the engine is hot. 2. Remove radiator cover. 3. Remove radiator shroud attaching screws and place radiator shroud close to engine. 4. Disconnect radiator upper and lower hoses and torque converter oil cooler pipes. 5. Remove radiator. 6. Installation is in reverse order of removal. 7. Fill radiator with coolant. 8. Run engine for a few minutes, and check for leaks. Refer to Changing Engine Coolant in Section MA. CO-5

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Nissan Forklift Internal Combustion F03 series Service Repair Manual

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