Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD) — part 26
VACUUM PUMP
EM-401
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• Tighten mounting bolts in numerical order as shown in the figure.
CAUTION:
Be sure to check that the vacuum pump is in contact with the
cylinder head before tightening the mounting bolts.
E1BIA0614ZZ
EM-402
< REMOVAL AND INSTALLATION >
[R9M]
OIL SEPARATOR
OIL SEPARATOR
Exploded View
INFOID:0000000010281995
Removal and Installation
INFOID:0000000010281996
REMOVAL
1.
Remove fuel injection cover.
2.
Remove PCV hose.
3.
Disconnect harness connector of fuel injector.
4.
Loosen oil separator insulator mounting bolts.
5.
Remove oil separator.
1.
Oil separator
2.
Oil filler plug
3.
PCV hose
4.
Gasket
5.
Cylinder head
A.
Refer to
B.
To turbocharger air inlet pipe
Refer to
for symbols in the figure.
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OIL SEPARATOR
EM-403
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• Loosen mounting bolts in the reverse order as shown in the
figure.
6.
Remove oil separator insulator.
INSTALLATION
1.
Install gaskets to oil separator.
CAUTION:
Check the gasket is not dropped.
2.
Install oil separator.
• 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.
: Engine front
E1BIA0610ZZ
: Engine front
1st step: 5.0 N·m (0.51 kg-m, 44 in-lb)
2nd step: 10.0 N·m (1.0 kg-m, 7 ft-lb)
E1BIA0610ZZ
EM-404
< REMOVAL AND INSTALLATION >
[R9M]
INJECTION TUBE AND FUEL INJECTOR
INJECTION TUBE AND FUEL INJECTOR
Exploded View
INFOID:0000000010281997
Removal and Installation
INFOID:0000000010281998
REMOVAL
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to
EM-364, "Precaution for Diesel Equip-
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• It is forbidden to open an fuel injector. If you open an fuel injector by mistake, you will have to
change it.
NOTE:
It is possible to replace a single injection tube.
1.
Oil separator
2.
Fuel injector spacer
3.
Injection tube (center) bolt
4.
Injection rail protector seal
5.
Cylinder head
6.
Fuel hose
7.
Fuel rail pressure sensor
8.
Injection rail protector seal
9.
Injection rail
10. injection rail bolts
11.
Bracket
12. Injection rail protector seal
13. Clip
14. Fuel hose
15. Fuel injector support bolt
16. Fuel return hose
17. Clip
18. Injector
19. Fuel injector support
20. Injection tube
21. Injection tube (center)
22. Fuel hose
A.
B.
Refer to
C.
To fuel pump
Refer to
for symbols in the figure.
E1BIA1210GB
INJECTION TUBE AND FUEL INJECTOR
EM-405
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1.
Remove the battery. Refer to
PG-155, "Removal and Installation"
.
2.
Remove oil separator. Refer to
.
3.
Remove fuel return hose.
• Move without removing the fuel return hose clip using a flate
bade screwdriver.
4.
Disconnect and remove fuel hose.
5.
Remove fuel collector and injection tube (center).
6.
Remove injection tube (No. 1, 2, 3, 4).
• Put a paint mark or tag on injection tubes to identify each cylinder.
7.
Remove fuel injectors with the following procedure:
a.
Remove fuel injector. While rotating it to left and right, raise it to remove.
• If fuel injector spacer remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out.
CAUTION:
• Handle fuel injector carefully without giving an impact.
• Never disassemble fuel injector.
8.
Remove injection rail and injection rail protector.
9.
CAUTION:
In case of fuel rail pressure sensor fitted with a color ring:
• replacing the sensor is forbidden
• the injector rail must be completely replaced if the fuel rail pressure sensor fails.
10. Plug all the holes in the injection circuit.
INSTALLATION
1.
If an injector is remplaced, not the IMA code and the corresponding cylinder number and perform "injector
adjustement value registration". Refer to
NOTE:
IMA code are from X1 to XN
After connecting the battery programs the injectors using the diagnostic tool.
2.
Install fuel injector, injection tubes and fuel rail with the following procedure:
a.
Install fuel injector spacer to fuel injector, and insert them into cylinder head.
E1BIA0648ZZ
E1BIA0649ZZ
EM-406
< REMOVAL AND INSTALLATION >
[R9M]
INJECTION TUBE AND FUEL INJECTOR
CAUTION:
• Completely remove any foreign material among fuel injector and cylinder head.
•
b.
Install injection rail, injection tube (center).
• Finger tighten until contact the injection tube nuts.
c.
Install fuel injector support.
CAUTION:
Be sure to fit fuel injector support without looseness.
d.
NOTE:
In case of cylinder head replacement, pre-tighten the fuel injector support bolt and after loosen the fuel
injector support bolt.
Tighten fuel injector support bolt.
e.
Turn 180 degrees clockwise (angle tightening).
f.
Install injection tube (No. 1, 2, 3, 4) in the original position (temporarily).
• Finger tighten until contact the injection tube nuts.
CAUTION:
Never put injection tubes under stress.
g.
Tighten injection rail mounting bolts and all injection tube nuts (specified torque).
3.
Install fuel return hose onto fuel injectors with the following procedure.
• NOTE:
Failure to observe the following procedure may lead to an immobilising default.
• Fit the clip on the fuel return hose.
• Install fuel return hose onto fuel injectors.
• Always carry out a "push-pull" test (1), to check that the fuel
return hose is correctly fitted onto fuel injector.
• Always carry out a "push-pull" test, to check that the fuel return
hose is correctly fitted onto fuel hose.
4.
Install in the reverse order of removal, for the rest of parts.
Inspection
INFOID:0000000010281999
INSPECTION AFTER INSTALLATION
• When replacing fuel injector, this procedure must be performed. Refer to
EC9-143, "Special Repair Require-
• When replacing fuel injector, note the injector IMA code and the corresponding cylinder number.
NOTE:
IMA codes are from X1 to XN.
- Program the injectors using diagnostic tool.
Pre- tightening fuel injec-
tor support bolt (in case of
cylinder head replace-
ment)
20 Nm (2.0kg-m, 15 ft-lb)
Fuel injector support bolt
7Nm (0.7kg-m, 62 in-lb)
E1BIA0648ZZ
INJECTION TUBE AND FUEL INJECTOR
EM-407
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• Start the engine and check for fuel leak for one minute after starting.
CAUTION:
After any operation, check that there are no diesel leaks. Refer to
EM-364, "Precaution for Diesel
.
E1BIA0649ZZ
EM-408
< REMOVAL AND INSTALLATION >
[R9M]
FUEL PUMP
FUEL PUMP
Exploded View
INFOID:0000000010282000
Removal and Installation
INFOID:0000000010282001
REMOVAL
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to
EM-364, "Precaution for Diesel Equip-
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• Never disassemble or adjust the fuel pump body.
1.
Remove the battery. Refer to
PG-155, "Removal and Installation"
.
2.
Remove fuel injection cover.
3.
Remove air duct assembly and air cleaner case. Refer to
.
4.
Remove fuel collector. Refer to
.
5.
Disconnect fuel hoses from fuel pump. Refer to
and
.
6.
Remove the injection tube (center). Refer to
.
7.
Plug all the holes of the injection circuit.
8.
Remove the fuel pump.
1.
Fuel pump nut
2.
Fuel pump sprocket
3.
Fuel pump gasket
4.
Fuel collector
5.
Gasket
6.
Fuel pump
7.
Fuel pump
A.
To fuel tank
B.
To fuel filter
C.
To injection tube (center)
Refer to
for symbols in the figure.
E1BIA0445GB
FUEL PUMP
EM-409
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• Loosen mounting bolts in the reverse order as shown in the
figure.
9.
In case of replacement of the fuel pump you need to install the old fuel pump sprocket on the new fuel
pump. Refer to
EM-410, "Removal and Installation"
INSTALLATION
1.
Install fuel pump.
CAUTION:
Be sure to check that the fuel pump is in contact with the cylinder head before tightening the
mounting bolts.
• Tighten mounting bolts in two steps separately in numerical
order as shown in the figure.
2.
Install the injection tube (center). Refer to
• Finger tighten until contact the injection tube nuts.
3.
Install in the reverse order of removal, for the rest of parts.
4.
Perform "Fuel pump learning value clearing". Refer to
. when replacing fuel pump.
5.
When replacing or removing fuel pump, this procedure must be performed. Refer to
Inspection
INFOID:0000000010282002
INSPECTION AFTER INSTALLATION
• Start the engine and check for fuel leak for one minute after starting.
CAUTION:
After any operation, check that there are no diesel leaks. Refer to
EM-364, "Precaution for Diesel
.
E1BIA0609ZZ
25.0 N·m (2.6 kg-m, 18 ft-lb)
E1BIA0609ZZ
EM-410
< REMOVAL AND INSTALLATION >
[R9M]
FUEL PUMP SPROCKET
FUEL PUMP SPROCKET
Removal and Installation
INFOID:0000000010282003
REMOVAL
1.
Lock the high pressure fuel pump sprocket on the work-bench in
a vice with protective jaws.
2.
Using the tool [SST (Mot.1906)] (1), lock the high pressure fuel
pump sprocket.
Remove the high pressure fuel pump sprocket nut (2).
3.
Fit a separator (1) from the puller kit under the high pressure
fuel pump sprocket (2).
E1BIA0606ZZ
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E1BIA0220ZZ
FUEL PUMP SPROCKET
EM-411
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4.
Put the bracket (3) on the separator.
5.
Remove the high pressure fuel pump sprocket.
INSTALLATION
1.
Refit the sprocket to the newhigh pressure fuel pump.
2.
Screw in the new high pressure fuel pump sprocket on the work bench, without tightening it.
3.
Lock the high pressure fuel pump sprocket on the workbench in a vice with protective jaws.
4.
Torque tighten the high pressure fuel pump sprocket nut.
E1BIA0221ZZ
: 90 N·m (9.2 kg-m, 66 ft-lb)
EM-412
< REMOVAL AND INSTALLATION >
[R9M]
TIMING CHAIN
TIMING CHAIN
Exploded View
INFOID:0000000010282004
1.
Front cover bolt
2.
Front cover
3.
Exhaust camshaft timing sprocket
bolts
4.
Timing sprocket spacer
5.
Exhaust camshaft timing sprocket
(front)
6.
Exhaust camshaft timing sprocket
(rear)
7.
Exhaust camshaft
8.
Intake camshaft
9.
Intake camshaft timing sprocket
10. Intake camshaft timing sprocket
spacer
11.
Intake camshaft timing sprocket bolt 12. Timing chain tensioner guide and
timing chain guide bolts
13. Crankshaft
14. Timing chain guide
15. Crankshaft sprocket
16. Timing chain
17. Timing chain tensioner guide
18. Timing chain tensioner
19. Timing cover pin
20. Crankshaft spacer
21. Front oil seal
22. Timing chain tensioner bolts
23. Engine mounting bracket (RH)
E1BIA1211GB
TIMING CHAIN
EM-413
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NOTE:
Oil pump related parts cannot be removed with an onboard condition. Refer to
.
Removal and Installation
INFOID:0000000010282005
REMOVAL
1.
Drain engine oil. Refer to
.
CAUTION:
Perform this step when the engine is cold.
2.
Disconnect the battery cable from the negative terminal.
3.
Remove the following parts:
• Engine undercover
• Load wheel tire (RH)
• Fender protector (RH): Refer to
.
• Drive belt: Refer to
EM-373, "Removal and Installation"
.
• Fuel filter: Refer to
FL-46, "Removal and Installation"
4.
Remove crankshaft pulley with the following procedure:
a.
Set the crankshaft pulley locking tool [SST: — (Mot. 1770)] (A)
and loosen crankshaft pulley bolt.
b.
Remove crankshaft pulley and spacer.
• Pull crankshaft pulley with both hands to remove it.
CAUTION:
Be careful not to damage front oil seal lip.
5.
Remove front oil seal. Refer to
EM-427, "FRONT OIL SEAL : Removal and Installation"
.
• Set logs of the service tool (A) the front oil seal notches. Turn
counterclockwise until it locks.
NOTE:
The service tool is supplied in the new front oil seal parts kit.
6.
Remove the through bolt between lower torque rod and engine mounting bracket (rear), and hold the
engine mounting bracket (rear) with a transmission jack. Refer to
.
CAUTION:
Never hold the oil pan (lower).
7.
Remove the upper torque rod and the engine mounting insulator (RH). Refer to
.
8.
Remove engine mounting bracket and engine mounting stay (front and rear).
9.
Remove water pump pulley. Refer to
.
A.
B.
Refer to
C.
Refer to
JPBIA0730ZZ
JPBIA0765ZZ
EM-414
< REMOVAL AND INSTALLATION >
[R9M]
TIMING CHAIN
10. Remove front cover with the following procedure:
a.
Loosen front cover mounting bolts.
b.
Use the seal cutter [SST: KV10111100 ( — )] to cut liquid gasket for removal.
CAUTION:
Never use a screwdriver or something similar.
NOTE:
Unstick the front cover by hand, using a jerking motion to ensure it is not damaged.
11. Align the hole (1) on the exhaust camshaft timing sprocket
(front) with the hole (2) on the rocker cover.
• NOTE:
Turn the crankshaft clockwise using the tool [SST: —
(Mot.1770)].
12. Remove the TDC pin plug.
13. In place of plug, manually tighten the tool [SST: — (Mot.1970)].
14. Turn the crankshaft clockwise until it makes contact with the pin.
15. Make a mark:
• on the intake camshaft timing sprocket (1) and the rocker
cover (2) (vertically).
• on the hole (3) on the exhaust camshaft timing sprocket (front)
and on the rocker cover (4).
• Check the mark alignement (5) and (6).
16. Loosen the exhaust camshaft timing sprocket bolts (front).
17. Compress the timing chain tensioner (1) with timing chain ten-
sioner guide (2), and then insert a stopper pin (A) into hole on
timing chain tensioner.
NOTE:
Use approximately 3.0 mm (0.118 in) dia. hard metal pin as a
stopper pin
E1BIA0586ZZ
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JPBIA0727ZZ
TIMING CHAIN
EM-415
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18. Remove the timing chain with the following procedure:
a.
the timing hydraulic tensioner,
b.
the timing chain tensioner guide,
c.
the exhaust camshaft timing sprocket bolts,
d.
the timing sprocket spacer,
e.
the crankshaft spacer,
f.
the "Exhaust camshaft timing sprocket (front) - timing chain - crankshaft sprocket" assembly,
g.
the timing chain guide,
h.
the tool [SST: — (Mot.1970)].
INSTALLATION
1.
Set the engine at TDC.
2.
Install the tool [SST: — (Mot.1970)].
3.
Install timing chain guide.
4.
Tighten timing chain guide bolts.
5.
Install the crankshaft sprocket onto the crankshaft.
6.
Position:
a.
the timing chain on the crankshaft sprocket (align the sprocket
mark with the cooper chain link (1)).
b.
the timing chain on the exhaust camshaft timing sprocket (front)
(align the sprocket mark with the cooper chain link (1)).
7.
Install the exhaust camshaft timing sprocket (front) onto the exhaust camshaft.
8.
Place the timing sprocket spacer on the exhaust camshaft timing sprocket (front).
9.
Finger tighten the exhaust camshaft timing sprocket bolts.
NOTE:
Allow the timing sprocket to rotate freely.
10. Install the crankshaft spacer.
11. Install the timing chain tensioner guide.
12. Tighten the bolt of the timing chain tensioner guide.
Timing chain guide bolts: 25 N·m (2.6 kg-m, 18
ft-lb)
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EM-416
< REMOVAL AND INSTALLATION >
[R9M]
TIMING CHAIN
13. Install the timing hydraulic tensioner with its locking pin.
NOTE:
Check that the hydraulic tensioner is in contact with the cylinder block before tightening the bolts.
14. Tighten the bolts of the timing hydraulic tensioner.
15. Remove the locking pin.
16. Engage the collet of the tool [SST: — (Mot.1969)] (15) into the
exhaust camshaft groove.
17. Turn the tool to align the shafts on the spacer and the hole of the rocker cover.
18. Detach the collet of the tool from the exhaust camshaft groove.
19. Engage the pins of the tool in the holes in the intake camshaft timing sprocket.
NOTE:
Do not install the collet of the tool into the groove on the exhaust side of the camshaft.
20. Turn the tool to align the shafts on the spacer and the hole of the rocker cover.
21. Install the collet of the tool into the groove on the exhaust camshaft without forcing it (if necessary, start
the previous operation again).
22. Install the rocker cover onto the tool [SST: — (Mot.1969)].
23. Tighten the exhaust camshaft timing sprocket bolts.
24. Turn 40 degrees clockwise (angle tightening).
25. Remove:
a.
the bolts from the tool [SST: — (Mot.1969)],
b.
the tool [SST: — (Mot.1969)],
c.
the tool [SST: — (Mot.1970)],
26. Tighten the TDC hole plug.
Timing chain tensioner guide bolts: 25 N·m (2.6
kg-m, 18 ft-lb)
Timing hydraulic tensioner bolts: 10 N·m (1.0
kg-m, 7 ft-lb)
E1BIA0594ZZ
Exhaust camshaft timing sprocket bolts: 10 N·m
(10 kg-m, 7 ft-lb)
TDC hole plug: 25 N·m (2.6 kg-m, 18 ft-lb)
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