Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD) — part 23
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-353
< SERVICE DATA AND SPECIFICATIONS (SDS)
[K9K]
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VALVE LIFTER
Unit: mm (in)
VALVE CLEARANCE
Unit: mm (in)
AVAILABLE VALVE LIFTER
Unit: mm (in)
Camshaft cam height “A”
Intake
44.012 - 44.018 (1.7327 - 1.7329)
Exhaust
44.592 - 44.598 (1.7555 - 1.7557)
Items
Standard
SEM671
Items
Standard
Valve lifter outer diameter
34.965 - 34.985 (1.3767 - 1.3774)
Valve lifter hole diameter
35.000 - 35.040 (1.3780 - 1.3795)
Valve lifter clearance
0.015 - 0.075 (0.0006 - 0.0030)
Items
Cold
Intake
0.125 - 0.250 (0.0049 - 0.0098)
Exhaust
0.325 - 0.450 (0.0128 - 0.0177)
Part number
Thickness
13229BN700
7.550 (0.2972)
13229BN701
7.575 (0.2982)
13229BN702
7.600 (0.2992)
13229BN703
7.625 (0.3002)
13229BN704
7.650 (0.3012)
13229BN705
7.675 (0.3022)
13229BN706
7.700 (0.3031)
13229BN707
7.725 (0.3041)
13229BN708
7.750 (0.3051)
13229BN709
7.775 (0.3061)
13229BN710
7.800 (0.3071)
13229BN711
7.825 (0.3081)
13229BN712
7.850 (0.3091)
13229BN713
7.875 (0.3100)
13229BN714
7.900 (0.3110)
13229BN715
7.925 (0.3120)
13229BN716
7.950 (0.3130)
13229BN717
7.975 (0.3140)
EM-354
< SERVICE DATA AND SPECIFICATIONS (SDS)
[K9K]
SERVICE DATA AND SPECIFICATIONS (SDS)
Cylinder Head
INFOID:0000000010282110
CYLINDER HEAD
Unit: mm (in)
VALVE DIMENSIONS
13229BN718
8.000 (0.3150)
13229BN719
8.025 (0.3159)
13229BN720
8.050 (0.3169)
13229BN721
8.075 (0.3179)
13229BN722
8.100 (0.3189)
13229BN723
8.125 (0.3199)
13229BN724
8.150 (0.3209)
Part number
Thickness
Items
Standard
Cylinder head gasket thickness
0.68 - 0.74 (0.0269 - 0.0291)
Head surface distortion
Less than 0.05 (0.002)
Normal cylinder head height “H”
127 (5.000)
E1BIA0063ZZ
Items
Standard
Valve head diameter “D”
mm (in)
Intake
33.38 - 33.62 (1.314 - 1.324)
Exhaust
28.88 - 29.12 (1.137 - 1.146)
Valve length “L”
mm (in)
Intake
100.74 - 101.16 (3.9661 - 3.9827)
Exhaust
100.54 - 100.96 (3.9583 - 3.9748)
Valve stem diameter “d”
mm (in)
Intake
5.969 - 5.985 (0.2350 - 0.2356)
Measuring point (X1) is 41 (1.61)
Exhaust
5.955 - 5.971 (0.2344 - 0.2351)
Measuring point (X1) is 31 (1.22)
Valve seat angle “
α
”
degree
45
°
00
′
(45.00
°
)
Valve margin “T”
mm (in)
1.0 (0.039)
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-355
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[K9K]
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VALVE GUIDE
VALVE SEAT
Valve lift
mm (in)
Intake
8.0 (0.315)
Exhaust
8.6 (0.339)
Items
Standard
E1BIA0064ZZ
Items
Standard
Valve guide
mm (in)
Length
40.35 - 40.65 (1.5886 - 1.6004)
Outer diameter
10.956 - 11.062 (0.4313 - 0.4355)
Inner diameter (Finished
size)
6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter
mm (in)
11.0 (0.4431)
Valve guide clearance
mm (in)
Intake
0.020 - 0.050 (0.0008 - 0.0020)
Exhaust
0.030 - 0.063 (0.0012 - 0.0025)
Projection length “A”
mm (in)
Intake
14.0 (0.5512)
Exhaust
14.2 (0.5591)
Valve guide inclination angle “a”
degree
90
°
00
′
(90.00
°
)
E1BIA0065ZZ
Items
Standard
Cylinder head seat recess diameter “D”
mm (in)
Intake
34.444 - 34.474 (1.3561 - 1.3572)
Exhaust
29.955 - 29.985 (1.1793 - 1.1805)
Valve seat outer diameter “D”
mm (in)
Intake
34.534 - 34.550 (1.3596 - 1.3602)
Exhaust
30.035 - 30.048 (1.1825 - 1.1830)
Angle “
α
”
degree
89
°
30
′
(89.50
°
)
Contacting width “X”
mm (in)
1.8 (0.071)
Valve seat height “H”
mm (in)
Intake
4.61 - 4.69 (0.1815 - 0.1846)
Exhaust
5.63 - 5.71 (0.2217 - 0.2248)
EM-356
< SERVICE DATA AND SPECIFICATIONS (SDS)
[K9K]
SERVICE DATA AND SPECIFICATIONS (SDS)
VALVE SPRING
Cylinder Block
INFOID:0000000010282111
CYLINDER BLOCK
Unit: mm (in)
PISTON MARKING
Cylinder head seat recess depth “H”
mm (in)
Intake
6.0 (0.236)
Exhaust
7.0 (0.276)
Items
Standard
E1BIA0066ZZ
Items
Standard
Free height
mm (in)
43.31 (1.7051)
Pressure N (kg, lb) at height mm (in)
218 - 242 (22.2 - 24.7, 49.0 - 54.4) at 33.80 (1.3307)
477 - 523 (48.7 - 53.3, 107.2 - 117.6) at 24.80 (0.9764)
Spring squareness
mm (in)
1.2 (0.047)
Full pressed height
mm (in)
23.40 (0.9213)
Diameter of wire
mm (in)
3.45 (0.1358)
Outer diameter at the top of spring
mm (in)
20.8 - 21.2 (0.8189 - 0.8346)
Outer diameter at the bottom of spring
mm (in)
25.5 - 25.9 (1.0039 - 1.0197)
Inner diameter at the top of spring
mm (in)
13.9 - 14.3 (0.5472 - 0.5630)
Inner diameter at the bottom of spring
mm (in)
18.6 - 19.0 (0.7323 - 0.7480)
Items
Standard
Cylinder block top surface clearance
Less than 0.05 (0.002)
1
Direction of fitting of the piston mark towards the flywheel
2
Height between the piston pin and the top of the piston (see table below).
MBIB0337E
SERVICE DATA AND SPECIFICATIONS (SDS)
EM-357
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[K9K]
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PISTON
Unit: mm (in)
PISTON RING
Unit: mm (in)
PISTON PIN
Unit: mm (in)
3
Used by the supplier only
4
Used by the supplier only
5
Used by the supplier only
6
Piston axis of symmetry
7
Piston pin hole axis
8
Offset between the hole axis (7) and the piston's axis of symmetry (6) is 0.3 mm (0.012 in)
Items
Standard
Piston skirt diameter “A”
mm (in)
75.938 - 75.952 (2.9897 - 2.9902)
“a” dimension
mm (in)
56.0 (2.205)
Piston pin hole diameter
mm (in)
Category J
41.605 - 41.646 (1.6380 - 1.6396)
Category K
41.647 - 41.688 (1.6396 - 1.6413)
Category L
41.689 - 41.730 (1.6413 - 1.6429)
Category M
41.731 - 41.772 (1.6429 - 1.6446)
Category N
41.773 - 41.814 (1.6446 - 1.6462)
Capacity of combustion chamber
m
(Imp fl oz)
19.89 - 20.39 (0.78 - 0.80)
Piston protrusion
mm (in)
0.023 - 0.281 (0.009 - 0.011)
SEM882E
Items
Standard
Thickness
Top
1.97 - 1.99 (0.0776 - 0.0783)
2nd
1.97 - 1.99 (0.0776 - 0.0783)
Oil ring
2.47 - 2.49 (0.0972 - 0.0980)
Side clearance
Top
0.10 - 0.12 (0.0039 - 0.0047)
2nd
0.08 - 0.10 (0.0031 - 0.0039)
Oil ring
0.03 - 0.07 (0.0011 - 0.0027)
Piston ring end gap
Top
0.20 - 0.35 (0.0079 - 0.0138)
2nd
0.70 - 0.90 (0.0276 - 0.0354)
Oil ring
0.25 - 0.50 (0.0098 - 0.0197)
Items
Standard
Length
57.97 - 60.0 (2.282 - 2.362)
Piston pin outer diameter
25.995 - 26.000 (1.0234 - 1.0236)
EM-358
< SERVICE DATA AND SPECIFICATIONS (SDS)
[K9K]
SERVICE DATA AND SPECIFICATIONS (SDS)
CONNECTING ROD
Unit: mm (in)
CRANKSHAFT
Unit: mm (in)
Turbocharger
INFOID:0000000010282112
Items
Standard
Center distance
133.75 (5.266)
Connecting rod small end diameter (with bush)
26.013 - 26.025 (1.0241 - 1.0246)
Connecting rod big end diameter
47.610 - 47.627 (1.8744 - 1.8751)
Big end longitudinal play
0.205 - 0.467 (0.0081 - 0.0184)
Big end radial play
0.016 - 0.07 (0.0006 - 0.0027)
Items
Standard
Main journal diameter “Dm”
47.99 - 48.01 (1.8894 - 1.8902)
Pin journal diameter “Dp”
43.96 - 43.98 (1.7307 - 1.7315)
Maximum run-out allowed on the flywheel bearing face of the flywheel
0.6 (0.024)
Lateral play (without lateral shim)
0.045 - 0.252 (0.0018 - 0.0099)
Lateral play (with lateral shim)
0.045 - 0.852 (0.0018 - 0.0335)
Journal radial play
0.010 - 0.054 (0.0004 - 0.0021)
E1BIA0067ZZ
Items
Standard
Regulation value operating vacuum
kPa (bar, kg/cm
2
, psi)
40 (0.4, 0.4, 5.8)
Valve rod moving length
mm (in)
1.4 (0.055)
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
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SYMPTOM DIAGNOSIS
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting - Engine Noise
INFOID:0000000010281953
JPBIA0854GB
EM-360
< SYMPTOM DIAGNOSIS >
[R9M]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Use the Chart Below to Help You Find the Cause of the Symptom
INFOID:0000000010281954
1.
Locate the area where noise occurs.
2.
Confirm the type of noise.
3.
Specify the operating condition of engine.
4.
Check specified noise source.
If necessary, repair or replace these parts.
A: Closely related
B: Related
C: Sometimes related
—: Not related
Location
of noise
Type of
noise
Operating condition of engine
Source of
noise
Check item
Refer-
ence page
Before
warm-
up
After
warm-
up
When
start-
ing
When
idling
When
racing
While
driving
Top of en-
gine
Cylinder
head
Ticking or
clicking
A
C
—
B
B
—
Hydraulic
tappet
noise
Out of oil
Rattle
C
A
—
A
B
C
Camshaft
bearing
noise
Camshaft journal oil
clearance
Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil pan
Slap or
knock
—
A
—
B
B
—
Piston pin
noise
Piston to piston pin oil
clearance
Connecting rod bushing
oil clearance
Slap or
rap
A
—
—
B
B
A
Piston
slap noise
Piston ring side clear-
ance
Piston ring end gap
Knock
A
B
C
B
B
B
Connect-
ing rod
bearing
noise
Connecting rod bushing
oil clearance
Connecting rod bearing
oil clearance
Knock
A
B
—
A
B
C
Main bear-
ing noise
Main bearing oil clear-
ance
Front of
engine
Front cov-
er
Tapping or
ticking
A
A
—
B
B
B
Timing
chain and
chain ten-
sioner
noise
Timing chain cracks
and wear
Timing chain tensioner
operation
Front of
engine
Squeak-
ing or fizz-
ing
A
B
—
B
—
C
Drive belt
(Sticking
or slip-
ping)
Drive belt deflection
Creaking
A
B
A
B
A
B
Drive belt
(Slipping)
Idler pulley bearing op-
eration
Squall
Creak
A
B
—
B
A
B
Water
pump
noise
Water pump operation
PRECAUTIONS
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PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"
INFOID:0000000010499455
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. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
• 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 “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never 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.
Precautions for Removing Battery Terminal
INFOID:0000000010508841
• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.
• When disconnecting the 12V battery terminal, turn off the ACC
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.
INSTRUCTION 1
1.
Open the hood.
SEF289H
EM-362
< PRECAUTION >
[R9M]
PRECAUTIONS
2.
Turn key switch to the OFF position with the driver side door opened.
3.
Get out of the vehicle and close the driver side door.
4.
Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
5.
Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
1.
Unlock the door with intelligent key or remote keyless entry.
NOTE:
At this moment, ACC power is supplied.
2.
Open the driver side door.
3.
Open the hood.
4.
Close the driver side door.
5.
Wait at least 3 minutes.
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
6.
Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
Precaution for Procedure without Cowl Top Cover
INFOID:0000000010499453
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000010281956
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-
THEFT SYSTEM).
• Remove and install all control units after disconnecting both battery cables with the ignition switch
in the LOCK position.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
D4D engine
: 20 minutes
HRA2DDT
: 12 minutes
K9K engine
: 4 minutes
M9R engine
: 4 minutes
R9M engine
: 4 minutes
V9X engine
: 4 minutes
PIIB3706J
PRECAUTIONS
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For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1.
Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2.
Use the Intelligent Key or mechanical key to turn the ignition switch to the ACC position. At this time, the
steering lock will be released.
3.
Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4.
Perform the necessary repair operation.
5.
When the repair work is completed, return the ignition switch to the LOCK position before connecting the
battery cables. (At this time, the steering lock mechanism will engage.)
6.
Perform a self-diagnosis check of all control units using CONSULT.
Parts Requiring Angular Tightening
INFOID:0000000010281957
• Use an angle wrench for the final tightening of the following engine parts.
- Cylinder head bolts
- Main bearing cap bolts
- Timing sprocket bolts
- Crankshaft pulley bolt
- Wear compensation gear bolt
- Camshaft sprocket (for fuel pump) bolt
• 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.
Precaution for Liquid Gasket
INFOID:0000000010281958
REMOVAL OF LIQUID GASKET
• 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 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 is difficult to use, use a plastic ham-
mer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
JPBIA0052ZZ
EM-364
< PRECAUTION >
[R9M]
PRECAUTIONS
1.
Using a scraper (A), 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
gasket 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 to the tube presser (commercial service
tool).
Use Genuine Liquid Gasket or equivalent.
4.
Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
• If there is a groove for the liquid gasket application, apply the
gasket to the groove.
• As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes.
Check to read the instruction in this manual.
• Within five minutes of gasket application, install the mating
component.
• If the liquid gasket protrudes, wipe it off immediately.
• Do not retighten after the installation.
• After 30 minutes or more have passed from the installation, fill the engine oil and coolant.
CAUTION:
If there are instructions in this manual, observe them.
Precaution for Diesel Equipment
INFOID:0000000010281959
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 fuel filter to the fuel injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
• Metal or plastic chips
• Paint
• Fibers:
- Boxes
- Brushes
JPBIA0053ZZ
EMA0622D
A
: Groove
B
: Bolt hole
: Inside
JPBIA0010ZZ
PRECAUTIONS
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- Paper
- Clothing
- Cloths
• Foreign bodies such as hair
• Ambient air
• Etc.
WARNING:
It is not possible to clean the engine using a high pressure washer because of the risk of damaging
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
• Check that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores). 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.
• Check 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 fuel 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 system.
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.
• 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. 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.
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PRECAUTIONS
SPECIAL FEATURES
CAUTION:
• The engine must not operate with:
- Diesel fuel other than those required by the regulations for cetane number. Refer to
.
- Petrol, even in tiny quantities
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PRECAUTIONS
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• Before carrying out any work, check that the fuel rail is not under pressure and that the fuel temper-
ature is not too high. [The system can inject the diesel into the engine at a pressure up to 160,000
kPa (1,600 bar, 1,632 kg/cm
2
, 23,200 psi)].
• Respect the cleaning and safety advice specified in this document for any work on the high pressure
injection system.
• Remove of the interior of the fuel pump and fuel injectors is prohibited.
• For safety reasons, it is strictly forbidden to slacken an injection tube union when the engine is run-
ning.
• It is not possible to remove the fuel pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the fuel pressure sensor fails, the fuel pressure sensor, the fuel rail
and the fuel injection tubes must be replaced.
• It is strictly forbidden to remove the fuel pump pulley.
• 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.
CHECKING SEALING AFTER REPAIR
CAUTION:
After any operation, check that there is no diesel leakage.
• Start the engine and check for fuel leak for one minute after starting.
• Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
• Once the engine coolant temperature is above 50
°
C (122F) and provided there are no malfunctions present,
carry out a road test, taking the engine speed up to 4,000 rpm at least once to check that there is no leak-
age.
• Perform a visual inspection after the road test to check that there is no high pressure leakage.
• Clean off the tracing fluid.
Precautions For Engine Service
INFOID:0000000010281960
DISCONNECTING FUEL PIPING
• 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.
DRAINING ENGINE COOLANT
Drain engine coolant and engine oil when the engine is cooled.
INSPECTION, REPAIR AND REPLACEMENT
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
REMOVAL AND DISASSEMBLY
• 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.
• Must cover openings of engine system with a tape or equivalent, 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.
ASSEMBLY AND INSTALLATION
• 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.
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< PRECAUTION >
[R9M]
PRECAUTIONS
• 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.
• After disassembling, or exposing any internal engine parts, change engine oil and replace oil filter with a new
one.
• 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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