Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD) — part 25
EGR SYSTEM
EM-385
< REMOVAL AND INSTALLATION >
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EGR SYSTEM
Exploded View
INFOID:0000000010281977
Removal and Installation
INFOID:0000000010281978
REMOVAL
1.
Drain engine coolant. Refer to
.
CAUTION:
Perform this step when the engine is cold.
2.
Remove battery. Refer to
PG-155, "Removal and Installation"
.
3.
Remove air inlet tube from turbocharger. Refer to
1.
EGR volume control valve
2.
Turbocharger air inlet pipe
3.
EGR low pressure assembly bracket
4.
Gasket
5.
EGR cooler
6.
EGR cooler outlet temperature sen-
sor
7.
Diesel particulate filter
8.
Water hose
9.
EGR heat shield
10. Water hose
11.
Intake manifold
12. Gasket
13.
EGR low pressure volume control
valve
Refer to
for symbols in the figure.
E1BIA1202GB
EM-386
< REMOVAL AND INSTALLATION >
[R9M]
EGR SYSTEM
4.
Remove air duct assembly. Refer to
.
5.
Remove cowl top cover and extension cowl top. Refer to
EXT-29, "Removal and Installation"
.
6.
Remove diesel particle filter. Refer to
EX-24, "Removal and installation"
.
7.
Remove the swirl valve. Refer to
8.
Remove EGR volume control valve on the intake manifold.
CAUTION:
• Handle carefully to avoid any shock to EGR volume control valve.
• Never disassemble EGR volume control valve.
• Cover engine openings to avoid entry of foreign materials.
9.
Remove low pressure EGR volume control valve on the EGR cooler.
CAUTION:
• Handle carefully to avoid any shock to EGR volume control valve.
• Never disassemble EGR volume control valve.
• Cover engine openings to avoid entry of foreign materials.
10. Remove EGR heat shield.
11. Disconnect water hose on the EGR cooler.
12. Remove EGR cooler outlet temperature sensor.
13. Remove EGR cooler.
14. Remove EGR cooler tube.
• Loosen mounting bolts in reverse order as shown in the figure.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Clean each joint surface before installation.
1.
Perform "EGR volume control valve position learning". Refer to
. when remov-
ing or replacing EGR volume control valve.
2.
Perform "Low pressure EGR volume control valve position learning". Refer to
. when removing or replacing low pressure EGR volume control.
INTAKE MANIFOLD
EM-387
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INTAKE MANIFOLD
Exploded View
INFOID:0000000010281979
Removal and Installation
INFOID:0000000010281980
REMOVAL
1.
Remove air duct (inlet). Refer to
.
2.
Remove air inlet hose 1 and air inlet tube 1. Refer to
3.
Use a refrigerant equipment to discharge the refrigerant.
4.
Remove low pressure flexible hose fixing bolt from compressor and high pressure flexible hose fixing bolt
from compressor.
5.
Put aside low pressure flexible hose and high pressure flexible hose.
6.
Remove throttle valve from intake manifold.
7.
Remove swirl valve from intake manifold.
8.
Remove EGR volume controle valve from intake mainifold.
CAUTION:
1.
Intake manifold
2.
gasket
3.
Cylinder head
4.
Throttle valve
5.
O-ring
6.
Swirl valve
7.
Air inlet pressure and temperature
sensor
8.
Gasket
9.
EGR volume controle valve
10. Gasket
11. Gasket
A.
Refer to
B.
Refer to
Refer to
for symbols in the figure.
E1BIA1203GB
EM-388
< REMOVAL AND INSTALLATION >
[R9M]
INTAKE MANIFOLD
• Handle carefully to avoid any shock to EGR volume control valve.
• Never disassemble EGR volume control valve.
9.
Disconnect coolant outlet unit regulation solenoide valve con-
nector (1).
10. Unclip coolant outlet unit regulation solenoide valve connector
harness (2) and put aside.
11. Unclip water hose (3) from coolant outlet unit regulation sole-
noide valve bracket (4).
12. Disconnect vacuum hose (5) from coolant outlet unit regulation
solenoide valve.
13. Remove coolant outlet unit regulation solenoide valve (6) and
bracket (4) assembly.
14. Remove oil level gauge and oil level gauge guide.
15. Remove water hose from intake manifold.
16. Disconnect terminal nut and connector from the alternator.
17. Remove engine harness bracket nuts (1) and bolt (3).
18. Unclip coolant temperature sensor (3).
19. Put aside engine harness.
20. Unclip vacuum hose on the intake manifold and put aside.
21. Remove intake manifold with the following procedure:
a.
Loosen mounting nuts in reverse order as shown in the figure.
b.
Remove intake manifold and gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Clean each joint surface before installation.
• Replace intake manifold stud if loosened.
Intake Manifold
E1BIA0612ZZ
E1BIA0613ZZ
: Engine front
E1BIA0579ZZ
: 8 N·m ( 0.8 kg-m, 71 in-lb)
INTAKE MANIFOLD
EM-389
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1.
Install gasket to cylinder head as shown in the figure.
2.
Install intake manifold.
• Tighten mounting nuts in two steps separately.
3.
Perform "Throttle valve position learning". Refer to
. and "Swirl control valve
position learning". Refer to
. when removing or replacing throttle valve or swirl
valve.
4.
Perform "EGR volume control valve position learning". Refer to
. when remov-
ing or replacing EGR volume control valve.
5.
When replacing EGR volume control valve, throttle valve or swirl valve, this procedure must be per-
formed. Refer to
EC9-143, "Special Repair Requirement List"
Inspection
INFOID:0000000010281981
INSPECTION AFTER REMOVAL
Surface Distortion
• Check the surface distortion of the intake manifold mating surface with a straightedge and a feeler gauge.
• If it exceeds the standard, replace intake manifold.
: Engine front
E1BIA0580ZZ
: Engine front
First step: 10 N·m ( 1.0 kg-m, 7 ft-lb)
E1BIA0579ZZ
Second step: 25 N·m ( 2.6 kg-m, 18 ft-lb)
Standard
EM-390
< REMOVAL AND INSTALLATION >
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TURBOCHARGER
TURBOCHARGER
Exploded View
INFOID:0000000010281982
Removal and Installation
INFOID:0000000010281983
REMOVAL
1.
Disconnect the battery from negative terminal.
2.
Remove air inlet tube from turbocharger. Refer to
1.
Turbocharger air inlet pipe
2.
Air inlet pipe 1
3.
Diesel particle filter bracket
4.
Turbocharger
5.
Oil tube
6.
Exaust gas pressure sensor
7.
Gasket
8.
Oil tube
9.
Exhaust gas pressure sensor tube
10. Exhaust gas temperature sensor
11.
Oil tube
12. O-ring
13. Exhaust manifold
14. Exhaust manifold gasket
15. Exhaust manifold heat shield gas-
ket
A.
EM-390, "Removal and Installa-
B.
C.
Refer to
D.
EM-390, "Removal and Installa-
Refer to
for symbols in the figure.
E1BIA1204GB
TURBOCHARGER
EM-391
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3.
Remove air duct assembly. Refer to
.
4.
Remove cowl top cover and extension cowl top. Refer to
EXT-29, "Removal and Installation"
.
5.
Disconnect vacuum hose from turbocharger.
6.
Remove exhaust front tube. Refer to
EX-22, "Removal and Installation"
7.
Remove diesel particle filter. Refer to
EX-24, "Removal and installation"
8.
Remove oil tube from turbocharger.
9.
Remove exhaust gas temperature sensor. Refer to
EX-27, "EXHAUST GAS TEMPERATURE SENSOR
ON THE EXHAUST GAS COOLER : Removal and installation"
.
10. Remove exhaust gas pressure sensor and exhaust gas pressure tube assembly. Refer to
CAUTION:
Be careful not to impact or damage exhaust gas pressure sensor.
11. Remove turbocharger from exhaust manifold.
CAUTION:
Never disassemble or adjust the turbocharger body.
INSTALLATION
Note the following and install in the reverse order of removal.
CAUTION:
• Clean each joint surface before installation.
• Replace turbocharger stud if loosened.
1.
Install turbocharger.
• Tighten the mounting nuts in two steps separately.
Inspection
INFOID:0000000010281984
INSPECTION AFTER REMOVAL
Turbocharger
Check there is no leakage on the different side of the turbocharger (exhaust gas and oil)
: 9 N·m ( 0.9 kg-m, 80 in-lb)
1st step: 15.0 N·m (1.5 kg-m, 11 ft-lb)
2nd step: 25.0 N·m (2.6 kg-m, 18 ft-lb)
E1BIA0653ZZ
EM-392
< REMOVAL AND INSTALLATION >
[R9M]
TURBOCHARGER
CAUTION:
When the compressor wheel, turbine wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
Turbocharger Boost Control
• Connect the handy vacuum pump (A) to the actuator, and check
that the rod strokes smoothly in compliance with the following
pressure.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.
Suction side:
Between turbocharger and air cleaner
Between turbocharger and charge air cleaner
Exhaust side:
Between turbocharger and diesel particle filter
Between turbocharger and exhaust manifold
Standard (value of vacuum/value of rod moving):
JPBIA0665ZZ
EXHAUST MANIFOLD
EM-393
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EXHAUST MANIFOLD
Exploded View
INFOID:0000000010281985
Removal and Installation
INFOID:0000000010281986
REMOVAL
1.
Disconnect battery negative terminal.
2.
Remove diesel particle filter. Refer to
EX-24, "Removal and installation"
3.
Remove turbocharger. Refer to
EM-390, "Removal and Installation"
.
4.
Remove air cleaner case. Refer to
EM-380, "Removal and Installation"
.
5.
Remove exhaust gas pressure sensor. Refer to
EX-29, "Removal and installation"
6.
Remove exhaust gas temperature sensor. Refer to
EX-27, "EXHAUST GAS TEMPERATURE SENSOR
ON THE EXHAUST GAS COOLER : Removal and installation"
7.
Remove exhaust manifold.
1.
Exhaust manifold gasket
2.
Exhaust manifold
3.
Exhaust manifold heat shield gasket
4.
Cylinder head
A.
B.
Refer to
C.
Refer to
E1BIA1205GB
EM-394
< REMOVAL AND INSTALLATION >
[R9M]
EXHAUST MANIFOLD
• Loosen mounting nuts in the reverse order as shown in the fig-
ure.
8.
Remove gasket.
CAUTION:
• Cover engine openings to avoid entry of foreign materials.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
• Clean each joint surface before installation.
• Replace exhaust manifold stud if loosened.
1.
Install gasket to cylinder head as shown in the figure.
2.
Install exhaust manifold.
• Tighten the mounting nuts in two steps separately in numerical
order as shown in the figure.
3.
Install in the reverse order of removal, for the rest of parts.
Inspection
INFOID:0000000010281987
INSPECTION AFTER REMOVAL
Surface Distortion
• Check the surface distortion of the exhaust manifold mating surface with a straightedge and a feeler gauge.
: Engine front
E1BIA0581ZZ
: 9 N·m ( 0.9 kg-m, 80 in-lb)
: Engine front
E1BIA0583ZZ
: Engine front
1st step: 15.0 N·m (1.5 kg-m, 11 ft-lb)
2nd step: 30.0 N·m (3.1 kg-m, 22 ft-lb)
E1BIA0581ZZ
Standard
: Refer to
EXHAUST MANIFOLD
EM-395
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• If it exceeds the standard, replace exhaust manifold.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.
EM-396
< REMOVAL AND INSTALLATION >
[R9M]
OIL PAN (LOWER) AND OIL STRAINER
OIL PAN (LOWER) AND OIL STRAINER
Exploded View
INFOID:0000000010281988
Removal and Installation
INFOID:0000000010281989
REMOVAL
1.
Remove engine undercover.
2.
Drain engine oil. Refer to
.
CAUTION:
Perform this step when engine is cold.
3.
Remove oil pan (lower) with the following procedure:
a.
Loosen mounting bolts in reverse order shown in the figure.
1.
Cylinder block
2.
Bush
3.
TDC pin plug
4.
Gasket
5.
Oil pan drain plug
6.
Oil pan (lower) bolt
7.
Oil pan (lower)
8.
Oil pan (upper)
9.
Oil pan (upper) bolt
A.
B.
Refer to
Refer to
for symbols in the figure.
E1BIA1206GB
E1BIA0582ZZ
OIL PAN (LOWER) AND OIL STRAINER
EM-397
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b.
Insert the seal cutter [SST:KV10111100 ( — )] (A) between oil
pan (upper) and oil pan (lower). Slide tool by tapping on the side
of the tool with a hammer.
CAUTION:
• Be careful not to damage mating surface.
• Never insert screwdriver, or oil pan flange will be
deformed.
c.
Remove oil pan (lower).
4.
Remove oil strainer.
• Loosen mounting bolt.
INSTALLATION
1.
Install oil strainer.
• Tighten oil strainer mounting bolts.
2.
Install oil pan (lower) with the following procedure:
a.
Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
CAUTION:
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
• Remove old liquid gasket from the bolt holes and threads.
JPBIA0276ZZ
E1BIA0647ZZ
: 10.0 N·m (1.0 kg-m, 7 ft-lb)
E1BIA0647ZZ
JPBIA0025ZZ
EM-398
< REMOVAL AND INSTALLATION >
[R9M]
OIL PAN (LOWER) AND OIL STRAINER
b.
Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) as shown in the figure.
Use Genuine Liquid Gasket or equivalent
CAUTION:
Attaching should be done within 5 minutes after coating.
c.
Tighten mounting bolts in two steps separately in numerical
order as shown in the figure.
3.
Install in the reverse order of removal, for the rest of parts.
NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.
Inspection
INFOID:0000000010281990
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSPECTION AFTER INSTALLATION
1.
Check the engine oil level and adjust engine oil. Refer to
.
2.
Start engine, and check there is no leak of engine oil.
3.
Stop engine and wait for 10 minutes.
4.
Check the engine oil level again. Refer to
a
: 3.0 - 7.0 mm (0.118 - 0.276 in)
: Engine front
JPBIA0648ZZ
1st step: 5.0 N·m (0.51 kg-m, 44 in-lb)
2nd step: 12.0 N·m (1.2 kg-m, 9 ft-lb)
E1BIA0582ZZ
GLOW PLUG
EM-399
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GLOW PLUG
Exploded View
INFOID:0000000010281991
Removal and Installation
INFOID:0000000010281992
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1.
Disconnect the battery cable from the negative terminal.
2.
Remove air inlet hose 1. Refer to
3.
Remove damper valve from intake manifold. Refer to
4.
Remove swirl valve from intake manifold. Refer to
5.
Disconnect harness connector from glow plug.
6.
Remove glow plug.
CAUTION:
• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal.
INSTALLATION
1.
Remove adhered carbon from glow plug installation hole with a reamer.
2.
Install glow plug.
3.
Install in the reverse order of removal, for the rest of parts.
1.
Glow plug
Refer to
E1BIA1207GB
EM-400
< REMOVAL AND INSTALLATION >
[R9M]
VACUUM PUMP
VACUUM PUMP
Exploded View
INFOID:0000000010281993
Removal and Installation
INFOID:0000000010281994
REMOVAL
1.
Remove battery. Refer to
PG-155, "Removal and Installation"
.
2.
Disconnect vacuum hoses.
3.
Remove vacuum pump.
• Loosen mounting bolts in reverse order as shown in the figure.
INSTALLATION
Note the following, and install in the reverse order of removal.
Vacuum pump
1.
Vacuum pump
2.
Gasket
3.
Vacuum hose
A.
To brake booster
B.
To turbocharger boost control sole-
noid valve
C.
To coolant outlet unit regulation sole-
noid valve
Refer to
for symbols in the figure.
E1BIA1208GB
E1BIA0614ZZ
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