Juke F15 (2012 year). Service Repair Manual — part 194
EM-252
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
*: Total indicator reading
Valve Lifter
Unit: mm (in)
Valve Clearance
Unit: mm (in)
*:Approximately 80
°
C (176
°
F)
Available Valve Lifter
Unit: mm (in)
Items
Standard
Valve lifter outer diameter
29.977 - 29.987 (1.1801 - 1.1805)
Valve lifter hole diameter
30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance
0.013 - 0.044 (0.0005 - 0.0017)
Cold
Hot * (reference data)
Intake
0.26 - 0.34 (0.010 - 0.013)
0.304 - 0.416 (0.012 - 0.016)
Exhaust
0.29 - 0.37 (0.011 - 0.014)
0.308 - 0.432 (0.012 - 0.017)
Identification mark (A)
Thickness (B)
300
3.00 (0.1181)
302
3.02 (0.1188)
304
3.04 (0.1196)
306
3.06 (0.1204)
308
3.08 (0.1212)
310
3.10 (0.1220)
312
3.12 (0.1228)
314
3.14 (0.1236)
316
3.16 (0.1244)
318
3.18 (0.1251)
320
3.20 (0.1259)
322
3.22 (0.1267)
324
3.24 (0.1275)
326
3.26 (0.1283)
328
3.28 (0.1291)
330
3.30 (0.1299)
332
3.32 (0.1307)
334
3.34 (0.1314)
336
3.36 (0.1322)
338
3.38 (0.1330)
JPBIA0170ZZ
SERVICE DATA AND SPECIFICATIONS (SDS)
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Cylinder head
INFOID:0000000006449946
CYLINDER HEAD
Unit: mm (in)
Valve Dimensions
Unit: mm (in)
Valve Guide
340
3.40 (0.1338)
342
3.42 (0.1346)
344
3.44 (0.1354)
346
3.46 (0.1362)
348
3.48 (0.1370)
350
3.50 (0.1377)
Identification mark (A)
Thickness (B)
Items
Limit
Head surface distortion
0.1 (0.004)
Valve head diameter “D”
Intake
31.0 - 31.3 (1.220 - 1.232)
Exhaust
25.3 - 25.6 (0.996 - 1.007)
Valve length “a”
Intake
101.73 (4.01)
Exhaust
102.49 (4.04)
“b”
Intake
1.0 (0.0393)
Exhaust
1.0 (0.0393)
“c”
Intake
2.1 - 2.8 (0.0826 - 0.1102)
Exhaust
2.3 - 3.0 (0.0905 - 0.1181)
“c
′
”
Intake
3.0 (0.1181)
Exhaust
–
“d ”
Intake
4.965 - 4.980 (0.1954 - 0.1960)
Exhaust
4.955 - 4.970 (0.1950 - 0.1956)
Valve seat angle “
α
”
Intake
45
°
15
′
- 45
°
45
′
Exhaust
PBIC3878E
EM-254
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
Valve Seat
Unit: mm (in)
Items
Standard part
Service part
Valve guide
Outer diameter
9.023 - 9.034 (0.3552 - 0.3556)
9.223 - 9.234 (0.3631 - 0.3635)
Inner diameter (Finished size)
5.000 - 5.018 (0.1968 - 0.1975)
Cylinder head valve guide hole diameter
8.975 - 8.996 (0.3533 - 0.3541)
9.175 - 9.196 (0.3612 - 0.3620)
Interference fit of valve guide
0.027 - 0.059 (0.0011 - 0.0023)
Items
Standard
Limit
Valve guide clearance
Intake
0.020 - 0.053 (0.0008 - 0.0021)
0.1 (0.004)
Exhaust
0.030 - 0.063 (0.0012 - 0.0025)
0.1 (0.004)
Projection length “H”
11.4 - 11.8 (0.448 - 0.464)
PBIC0184E
Items
Standard
Oversize [0.5 (0.02)] (Service)
Cylinder head seat recess diameter “D”
Intake
31.400 - 31.416 (1.2362 - 1.2368)
31.900 - 31.916 (1.2559 - 1.2565)
Exhaust
25.900 - 25.916 (1.0196 - 1.0203)
26.400 - 26.416 (1.0393 - 1.0399)
Valve seat outer diameter “d”
Intake
31.497 - 31.513 (1.2400 - 1.2406)
31.997 - 32.013 (1.2597 - 1.2603)
Exhaust
25.997 - 26.013 (1.0235 - 1.0241)
26.497 - 26.513 (1.0431 - 1.0438)
Valve seat interference fit
Intake
0.081 - 0.113 (0.0032 - 0.0044)
Exhaust
0.081 - 0.113 (0.0032 - 0.0044)
Diameter “d1”*
1
Intake
29.0 (1.141)
Exhaust
23.0 (0.905)
Diameter “d2”*
2
Intake
30.6 - 30.8 (1.204 - 1.212)
Exhaust
24.9 - 25.1 (0.980 - 0.988)
Angle “
α
1”
Intake
60
°
Exhaust
45
°
Angle “
α
2”
Intake
89
°
45
′
- 90
°
15
′
Exhaust
89
°
45
′
- 90
°
15
′
PBIC2745E
SERVICE DATA AND SPECIFICATIONS (SDS)
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*
1
: Diameter made by intersection point of conic angles
α
1 and
α
2
*
2
: Diameter made by intersection point of conic angles
α
2 and
α
3
*
3
: Machining data
Valve Spring
Standard:
Cylinder Block
INFOID:0000000006449947
CYLINDER BLOCK
Unit: mm (in)
Angle “
α
3”
Intake
120
°
Exhaust
120
°
Contacting width “W”*
3
Intake
1.05 - 1.35 (0.0413 - 0.0531)
Exhaust
1.25 - 1.55 (0.0492 - 0.0610)
Height “h”
Intake
6.0 (0.236)
5.45 (0.214)
Exhaust
6.0 (0.236)
5.43 (0.213)
Depth “H”
6.0 (0.236)
Free height
42.26 mm (1.6637 in)
Installation height
32.40 mm (1.2755 in)
Installation load
136 - 154 N (13.9 - 15.7 kg, 31 - 35 lb)
Height during valve open
23.96 mm (0.9433 in)
Load with valve open
262 - 296 N (26.7 - 30.2 kg, 59 - 67 lb)
Surface distortion
Limit
0.1 (0.004)
Cylinder bore
Inner diameter
Standard
78.000 - 78.015 (3.0708 - 3.0714)
Wear limit
—
Out-of-round (Difference between “a” and “b”)
Limit
0.015 (0.0006)
Taper (Difference between “c” and “d”)
0.010 (0.0004)
PBIC3924E
EM-256
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
Available Piston
Unit: mm (in)
Piston Ring
Unit: mm (in)
Piston Pin
Unit: mm (in)
Connecting Rod
Cylinder block main bearing housing inner diameter grade
Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
Grade No. P
Grade No. R
Grade No. S
Grade No. T
Grade No. U
Grade No. V
Grade No. W
51.997 - 51.998 (2.0471 - 2.0472)
51.998 - 51.999 (2.0472 - 2.0472)
51.999 - 52.000 (2.0472 - 2.0472)
52.000 - 52.001 (2.0472 - 2.0472)
52.001 - 52.002 (2.0473 - 2.0473)
52.002 - 52.003 (2.0473 - 2.0473)
52.003 - 52.004 (2.0474 - 2.0474)
52.004 - 52.005 (2.0474 - 2.0474)
52.005 - 52.006 (2.0474 - 2.0474)
52.006 - 52.007 (2.0475 - 2.0475)
52.007 - 52.008 (2.0475 - 2.0475)
52.008 - 52.009 (2.0476 - 2.0476)
52.009 - 52.010 (2.0476 - 2.0476)
52.010 - 52.011 (2.0476 - 2.0476)
52.011 - 52.012 (2.0477 - 2.0477)
52.012 - 52.013 (2.0477 - 2.0477)
52.013 - 52.014 (2.0478 - 2.0478)
52.014 - 52.015 (2.0478 - 2.0478)
52.015 - 52.016 (2.0478 - 2.0478)
52.016 - 52.017 (2.0479 - 2.0479)
Difference in inner diameter between cylinders
Standard
Less than 0.03 (0.0012)
Piston skirt diameter “A”
77.965 - 77.980 (3.0694 - 3.0700)
Piston height “H” dimension
37.1 (1.460)
Piston pin hole diameter
19.006 - 19.012 (0.7482 - 0.7485)
Piston to cylinder bore clearance
0.020 - 0.050 (0.0007 - 0.0019)
PBIC0188E
Items
Standard
Limit
Side clearance
Top
0.040 - 0.080 (0.0015 - 0.0031)
0.11 (0.0043)
2nd
0.030 - 0.070 (0.0012 - 0.0028)
0.10 (0.0039)
Oil (rail ring)
0.045 - 0.125 (0.0017 - 0.0049)
—
End gap
Top
0.20 - 0.30 (0.0078 - 0.0118)
0.50 (0.0196)
2nd
0.35 - 0.50 (0.0137 - 0.0196)
0.66 (0.0259)
Oil (rail ring)
0.20 - 0.60 (0.0079 - 0.0236)
0.92 (0.0362)
Piston pin outer diameter
18.996 - 19.002 (0.7478 - 0.7481)
Piston to piston pin oil clearance
Standard
0.008 - 0.012 (0.0003 - 0.0004)
Connecting rod bushing oil clearance
Standard
–0.018 to –0.044 (–0.0007 to –0.0017)
SERVICE DATA AND SPECIFICATIONS (SDS)
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Unit: mm (in)
*: After installing in connecting rod
Main Bearing
INFOID:0000000006449948
MAIN BEARING
Unit: mm (in)
Center distance
129.84 - 129.94 (5.1118 - 5.1157)
Bend [per 100 (3.94)]
Limit
0.15 (0.0059)
Torsion [per 100 (3.94)]
Limit
0.30 (0.0118)
Connecting rod bushing inner diameter*
18.958 - 18.978 (0.7463 - 0.7471)
Side clearance
Standard
0.200 - 0.352 (0.0079 - 0.0138)
Connecting rod big end diameter
Grade No. A
Grade No. B
Grade No. C
Grade No. D
Grade No. E
Grade No. F
Grade No. G
Grade No. H
Grade No. J
Grade No. K
Grade No. L
Grade No. M
Grade No. N
43.000 - 43.001 (1.6929 - 1.6929)
43.001 - 43.002 (1.6929 - 1.6930)
43.002 - 43.003 (1.6930 - 1.6930)
43.003 - 43.004 (1 6930 - 1.6931)
43.004 - 43.005 (1.6931 - 1.6931)
43.005 - 43.006 (1.6931 - 1.6931)
43.006 - 43.007 (1.6931 - 1.6932)
43.007 - 43.008 (1.6932 - 1.6932)
43.008 - 43.009 (1.6932 - 1.6933)
43.009 - 43.010 (1.6933 - 1.6933)
43.010 - 43.011 (1.6933 - 1.6933)
43.011 - 43.012 (1.6933 - 1.6934)
43.012 - 43.013 (1.6934 - 1.6934)
Grade number
Thickness
Identification color
Remarks
0
1.996 - 1.999 (0.0785 - 0.0787)
Black
Grade and color are the same
for upper and lower bearings.
1
1.999 - 2.002 (0.0787 - 0.0788)
Brown
2
2.002 - 2.005 (0.0788 - 0.0789)
Green
3
2.005 - 2.008 (0.0789 - 0.0790)
Yellow
4
2.008 - 2.011 (0.0790 - 0.0791)
Blue
5
2.011 - 2.014 (0.0791 - 0.0792)
Pink
SEM685D
EM-258
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
Undersize
Unit: mm (in)
Bearing Oil Clearance
Unit: mm (in)
Connecting Rod Bearing
INFOID:0000000006449949
CONNECTING ROD BEARING
Unit: mm (in)
01
UPR
1.996 - 1.999 (0.0785 - 0.0787)
Black
Grade and color are different
for upper and lower bearings.
LWR
1.999 - 2.002 (0.0787 - 0.0788)
Brown
12
UPR
1.999 - 2.002 (0.0787 - 0.0788)
Brown
LWR
2.002 - 2.005 (0.0788 - 0.0789)
Green
23
UPR
2.002 - 2.005 (0.0788 - 0.0789)
Green
LWR
2.005 - 2.008 (0.0789 - 0.0790)
Yellow
34
UPR
2.005 - 2.008 (0.0789 - 0.0790)
Yellow
LWR
2.008 - 2.011 (0.0790 - 0.0791)
Blue
45
UPR
2.008 - 2.011 (0.0790 - 0.0791)
Blue
LWR
2.011 - 2.014 (0.0791 - 0.0792)
Pink
Grade number
Thickness
Identification color
Remarks
SEM685D
Items
Thickness
Main journal diameter
US 0.25 (0.0098)
2.126 - 2.134 (0.0837 - 0.0840)
Grind so that bearing clearance is the specified value.
Main bearing oil clearance
Standard
0.024 - 0.034 (0.0009 - 0.0013)
Grade number
Thickness
Identification color
Remarks
0
1.498 - 1.501 (0.0590 - 0.0591)
Black
Grade and color are the same
for upper and lower bearings.
1
1.501 - 1.504 (0.0591 - 0.0592)
Brown
2
1.504 - 1.507 (0.0592 - 0.0593)
Green
3
1.507 - 1.510 (0.0593 - 0.0594)
Yellow
4
1.510 - 1.513 (0.0594 - 0.0596)
Blue
01
UPR
1.498 - 1.501 (0.0590 - 0.0591)
Black
Grade and color are different
between upper and lower bear-
ings.
LWR
1.501 - 1.504 (0.0591 - 0.0592)
Brown
12
UPR
1.501 - 1.504 (0.0591 - 0.0592)
Brown
LWR
1.504 - 1.507 (0.0592 - 0.0593)
Green
23
UPR
1.504 - 1.507 (0.0592 - 0.0593)
Green
LWR
1.507 - 1.510 (0.0593 - 0.0594)
Yellow
34
UPR
1.507 - 1.510 (0.0593 - 0.0594)
Yellow
LWR
1.510 - 1.513 (0.0594 - 0.0596)
Blue
SERVICE DATA AND SPECIFICATIONS (SDS)
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Undersize
Unit: mm (in)
Bearing Oil Clearance
Unit: mm (in)
Items
Thickness
Crankshaft pin journal diameter
US 0.25 (0.0098)
1.627 - 1.635 (0.0640 - 0.0644)
Grind so that bearing clearance is the specified value.
Connecting rod bearing oil clearance
Standard
0.029 - 0.039 (0.0011 - 0.0015)
Limit
0.10 (0.0039)
EM-260
< PRECAUTION >
[K9K]
PRECAUTIONS
PRECAUTION
PRECAUTIONS
Precaution for Procedure without Cowl Top Cover
INFOID:0000000006449950
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect
INFOID:0000000006449951
NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-
tion, then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.
OPERATION PROCEDURE
1.
Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2.
Turn the push-button ignition switch to ACC position.
(At this time, the steering lock will be released.)
3.
Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4.
Perform the necessary repair operation.
5.
When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6.
Perform self-diagnosis check of all control units using CONSULT-III.
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"
INFOID:0000000006449952
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 AIR BAG” and “SEAT BELT” of this
Service Manual.
WARNING:
PIIB3706J
PRECAUTIONS
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• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIR BAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
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)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Draining Engine Coolant
INFOID:0000000006449953
Drain engine coolant and engine oil when the engine is cooled.
Disconnecting Fuel Piping
INFOID:0000000006449954
• Before starting work, check no fire or spark producing items are in the work area.
• Release fuel pressure before disconnecting and disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.
Removal and Disassembly
INFOID:0000000006449955
• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
• Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
Inspection, Repair and Replacement
INFOID:0000000006449956
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Assembly and Installation
INFOID:0000000006449957
• Use torque wrench to tighten bolts or nuts to specification.
• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
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< PRECAUTION >
[K9K]
PRECAUTIONS
Parts Requiring Angle Tightening
INFOID:0000000006449958
• Use the angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
- Cylinder head bolts
- Lower cylinder block bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle
tightening)
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Liquid Gasket
INFOID:0000000006449959
REMOVAL OF LIQUID GASKET SEALING
• After removing mounting nuts and bolts, separate the mating sur-
face using the seal cutter [SST: KV10111100] (A) and remove old
liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
• Tap the seal cutter [SST: KV10111100] to insert it (B), and then
slide it (C) by tapping on the side as shown in the figure.
• In areas where the seal cutter [SST: KV10111100] is difficult to use,
lightly tap the parts using a plastic hammer to remove it.
CAUTION:
If for some unavoidable reason tool such as a screwdriver is
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
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.
3.
Attach liquid gasket tube to the tube presser (commercial ser-
vice tool).
Use Genuine Liquid Gasket or equivalent.
4.
Apply liquid gasket without gaps to the specified location accord-
ing to the specified dimensions.
• If there is a groove for liquid gasket application, apply liquid
gasket to the groove.
JPBIA0052ZZ
JPBIA0053ZZ
EMA0622D
PRECAUTIONS
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• As for bolt holes (B), normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Check to read the text of this manual.
• Within five minutes of liquid gasket application, install the mat-
ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Do not retighten mounting bolts or nuts after the installation.
• 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.
Precaution for Diesel Equipment
INFOID:0000000006449960
CLEANLINESS
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRES-
SURE DIRECT INJECTION SYSTEM
Risks relating to contamination
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
• Damage or destruction of the high pressure injection system and the engine,
• Seizing or leaking of a component.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (par-
ticles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter to the injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
• Metal or plastic chips,
• Paint,
• Fibres:
- Boxes,
- Brushes,
- Paper,
- Clothing,
- Cloths,
• Foreign bodies such as hair,
• Ambient air,
• Etc.
IMPORTANT: It is not possible to clean the engine using a high pressure washer because of the risk of dam-
aging connections. In addition, moisture may collect in the connectors and create electrical connection mal-
functions.
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYS-
TEM
• Ensure that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Nissan
part No.: 16830 BN700, Renault part No.: 77 01 206 804). Plugs are to be used once only. After use, they
must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable).
Unused plugs must be thrown away.
• Ensure that you have hermetically resealable plastic bags for storing removed parts. Stored parts will there-
fore be less subject to the risk of impurities. The bags must be used only once, and after use they must be
thrown away.
• Lint-free towelettes to be used for injection pump related service purpose. The use of a normal cloth or paper
for cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the sys-
tem. Each lint-free cloth should only be used once.
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
• For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
• Use a brush and thinners to clean the connections to be opened.
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• Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and
injection system zone). Check that no bristles remain adhered.
• Wash your hands before and during the operation if necessary.
• When wearing leather protective gloves, cover these with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
• As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system.
The plugs to be used are available from the Parts Stores - Nissan part No.: 16830 BN700, Renault part No.:
77 01 206 804. They must not, under any circumstances, be reused.
• Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries con-
tamination.
• All components of the injection system that are removed must be stored in a hermetically sealed plastic bag
once the plugs have been inserted.
• The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been
opened. These items are likely to allow impurities to enter the system.
• A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle.
Instructions for Fitting the Plugs
Nissan part number: 16830 BN700
(Renault part number: 77 01 206 804)
CAUTION:
• The engine must not run with:
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- Diesel containing more than 10% diester
- Petrol, even in very small amounts.
• The system can inject the diesel into the engine at a pressure of up to 140,000 kPa (1,400 bar, 1,428
kg/cm
2
, 20,300 psi). Before carrying out any work, check that the injector rail is no longer pressur-
ized and that the fuel temperature is not too high.
• You must respect the cleaning and safety advice specified in this document for any work on the high
pressure injection system.
SPECIAL FEATURES
CAUTION:
• The engine must not operate with:
- Diesel engine fuel containing more than 10% diester,
- Petrol, even in tiny quantities.
• The system can inject the diesel into the engine at a pressure up to 1400 bars. Before carrying out
any work, check that the injector rail is not under pressure and that the fuel temperature is not too
high.
• You must respect the cleaning and safety advice specified in this document for any work on the high
pressure injection system.
• Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the fuel tem-
perature sensor and the venturi can be replaced.
• For safety reasons, it is strictly forbidden to slacken a high pressure pipe union when the engine is
running.
• It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the pressure sensor fails, the pressure sensor, the rail and the five
high pressure pipes must be replaced.
• It is strictly forbidden to remove any injection pump pulley marked number 070 575. If the pump is
being replaced, the pulley must be replaced.
• It is forbidden to repair the wiring connecting the knock sensor (accelerometer) and the CKP sensor
(engine speed sensor). If the wiring should fail, it has to be replaced with new wiring.
• Applying 12 volts directly to any component in the system is prohibited.
• Ultrasonic carbon removal and cleaning are prohibited.
• Never start the engine without the battery being connected correctly.
• It is essential to replace all the disconnected air inlet plastic pipes.
There is a 16 digit code on the injectors called individual injector correction. This code is specific to
each injector, and takes into account differences in manufacture and specifies the flow injected by
each of them.
When an injector is replaced, it is necessary to program the code of the new injector into the ECM.
Refer to
INSTRUCTIONS FOR HIGH PRESSURE PIPES
CAUTION:
All the high pressure pipe removed must be systematically replaced along with the clips.
TIGHTENING THE HIGH PRESSURE PIPES
NOTE:
fit the pump/rail pipe before the rail/injector pipes.
Rail-pump pipe
• Undo the rail,
• Grease the threads of the high pressure pipe nuts,
• Insert the high pressure pipe olive into the taper of the high pressure pump outlet,
• Insert the high pressure pipe olive into the taper of the high pressure rail inlet.
• Move the nut into position by hand, on the rail side then the pump side,
• Tighten the rail,
• Tighten the high pressure pipe nuts on the rail side then on the pump side.
Rail/injector pipes
• Undo the rail,
• Grease the threads of the high pressure pipe nuts,
• Insert the high pressure pipe olive into the taper of the high pressure injector inlet,
• Insert the high pressure pipe olive into the taper of the high pressure rail outlet,
• Move the nuts into position by hand, on the injector side then the rail side,
• Tighten the rail,
• Ensure that the new clip, supplied with the new high pressure pipe, is fitted,
• Tighten the nuts of the high pressure pipes on the injector side first and then on the fuel rail side.
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NOTE:
Before fitting a new high pressure pipe, move back the nuts on the pipe then lightly lubricate the nut
threads with the oil from the sachet provided in the parts kit.
CHECKING SEALING AFTER REPAIR
CAUTION:
After any operation, check that there are no diesel leaks.
• Reprime the circuit using the priming pump.
• Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks.
• Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
• Once the engine coolant temperature is above 50
°
C and provided there are no malfunctions present, carry
out a road test, taking the engine speed up to 4000 rpm at least once to check that there are no leaks.
• Perform a visual inspection after the road test to make sure that there are no high pressure leaks.
• Clean off the tracing fluid.
REPLACING THE INJECTORS
NOTE:
Individual injector correction is a factory calibration carried out on each injector to adjust the flow of
each one precisely, taking into account differences in manufacture.
The correction values are written on a label affixed to each injector then entered in the ECM which can then
control each injector by taking account of their differences in manufacture.
The system can be programmed “WORK SUPPORT” mode with CONSULT-III.
The correction values (16 digit code) must be replaced after replacing an injector. Refer to
.
• Entering each injector's individual correction value, when replacing the ECM. Refer to
.
Parts To Be Replaced After Removal
INFOID:0000000006449961
• All gaskets
• Flywheel bolts
• Crankshaft bearing bolts
• Camshaft pulley bolt
• Crankshaft pulley bolts
• Big end cap bolts
• Injector holder copper washers
• Fuel injection tubes
• Pipe plugs
• Belts
• Timing belt tension wheel
• Oil jets
• Turbocharger plastic pipes
Installation of Thread Inserts
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Threaded holes on all engine component parts can be repaired by using thread inserts.
PREPARATION
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PREPARATION
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Special Service Tool
INFOID:0000000006449963
NISSAN tool number
(RENAULT tool No.)
Tool name
Description
KV113B0020
(Emb. 880)
Sliding hammer
Inertia extractor
KV113B0060
(Mot. 582-01)
Ring gear stopper
Flywheel immobilizing tool.
KV113B0110
(Mot. 1430)
TDC set pin
Set of TDC pins
KV113B0120
(Mot. 1485-01)
Oil jet remover
Tool for removing the piston bottom oil jets
KV113B0130
(Mot. 1489)
TDC set pin
TDC setting pin
KV113B0140
(Mot. 1492)
Bearing assembling set
Tool for installing connecting rod bearing
MBIB0358E
MBIB0363E
MBIB0372E
MBIB0373E
MBIB0374E
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