Nissan Qashqai J11. Manual - part 81

PRECAUTIONS

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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. Make
sure 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:0000000010282046

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,
• Fibers:
- 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.: 16609 00Q0B, Renault part No.: 77 01 476 857). 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.

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PRECAUTIONS

• 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 high pressure supply 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 - Nissan part No.: 16609 00Q0B, Renault part No.:
77 01 476 857. 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: 16609 00Q0B

PRECAUTIONS

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(Renault part number: 77 01 476 857)

CAUTION:

• The engine must not run with:
- 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

, 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.

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PRECAUTIONS

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 injection tube union when the engine is run-

ning.

• 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
injection tubes must be replaced.

• It is strictly forbidden to remove any high pressure supply 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.
INSTRUCTIONS FOR INJECTION TUBES

CAUTION:

All the injection tube removed must be systematically replaced along with the clips.
TIGHTENING THE INJECTION TUBES
NOTE:
fit the pump/rail pipe before the rail/injector pipes.
Rail-pump pipe
• Undo the rail,
• Grease the threads of the injection tube nuts,
• Insert the injection tube olive into the taper of the high pressure pump outlet,
• Insert the injection tube 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 injection tube nuts on the rail side then on the pump side.
Rail/injector pipes
• Undo the rail,
• Grease the threads of the injection tube nuts,
• Insert the injection tube olive into the taper of the high pressure injector inlet,
• Insert the injection tube 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 injection tube, is fitted,
• Tighten the nuts of the injection tubes on the injector side first and then on the fuel rail side.
NOTE:
Before fitting a new injection tube, 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.

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