Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD) - part 3

TURBOCHARGER

EM-33

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TURBOCHARGER

Exploded View

INFOID:0000000010287261

Refer to 

GI-4, "Components"

 for symbol marks in the figure.

Removal and Installation

INFOID:0000000010287262

REMOVAL

1.

Drain engine coolant. Refer to 

CO-11, "Draining"

.

2.

Remove engine undercover.

3.

Remove air inlet hose. Refer to 

EM-27, "Removal and Installation"

.

4.

Remove air cleaner filter unit assembly and air duct. Refer to 

EM-23, "Exploded View"

.

5.

Remove turbocharger heat shield.

1.

Water hose

2.

Air duct

3.

Exhaust gas pressure take off hose

4.

Wastegate hose

5.

Air inlet hose

6.

Exhaust manifold and turbocharger 
assembly gasket

7.

Oil supply tube

8.

Exhaust manifold and turbocharger 
assembly

9.

Oil return pipe

10. Water hose

11.

Turbocharger water pipe 

E1BIA1024GB

EM-34

< REMOVAL AND INSTALLATION >

[HRA2DDT]

TURBOCHARGER

6.

Disconnect from turbocharger:
• Exhaust gas pressure take off hose.
• Wastegate control hose.

7.

Remove cowl top extension. Refer to 

EXT-29, "Removal and Installation"

.

8.

Remove exhaust front tube. Refer to 

EX-6, "Exploded View"

.

9.

Remove catalyst converter and catalyst converter support bracket.Refer to 

EM-31, "Exploded View"

.

10. Remove turbocharger assembly as follows. Refer to 

EM-33, "Exploded View"

:

a.

Remove oil return tube and oil supply tube.

b.

Disconnect water hose from turbocharger.

c.

Remove mounting nuts of exhaust manifold in the reverse order
as shown in the figure. 

d.

Remove turbocharger and exhaust manifold assembly.

e.

Remove exhaust manifold gasket.

CAUTION:

• Be careful not to impact or damage tubocharger when removing.
• Never disassemble the turbocharger body.

INSTALLATION

CAUTION:

Never reuse gasket, oil tube and water pipe.

Note the following, and Install in the reverse order of removal.

1.

Install turbocharger and exhaust manifold assembly as follows:
1.

Install new exhaust manifold gasket.

2.

Tighten exhaust manifold bolts in the numerical order as
shown in the figure.

3.

Torque tighten exhaust manifold bolts. Refer to 

EM-37,

"Exploded View"

.

Inspection

INFOID:0000000010287263

INSPECTION PROCERDURE

Trouble Diagnosis of Turbocharger
Check items before trouble diagnosis 

1.

Check that the engine oil level is between L (Low level) and H (High level) of the oil level gauge. [When
the engine oil amount is more then H (High level), the engine oil flows into the inlet duct through the blow-
by gas passage, and the turbocharger is misjudged failure.] 

2.

Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.

E1BIA1011ZZ

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TURBOCHARGER

EM-35

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• Replace the exhaust manifold and turbocharger assembly when any malfunction is found after unit

inspections specified in the table below.

• If no malfunction is found after the unit inspections, judge that the turbocharger body has no non-stan-

dard conditions. Check the other parts again.

INSPECTION AFTER REMOVAL

Turbocharger

Inspection Location

Result

Symptoms likely to occur when the results shown on 

the left exist.

Oil leakage

Smoke

Noise

Poor pow-

er

Poor ac-

celeration

Turbine wheel

Wet with oil.

C

A

C

C

Carbon deposits observed.

C

A

B

B

“Rubs against” housing.

C

B

A

B

Vane is bent or broken.

A

A

Compressor wheel

Inside of intake port is badly stained 
with oil.

B

B

“Rubs against” housing.

C

B

A

B

Vane is bent or broken.

A

A

Check both turbine and compres-
sor rotor shaft end play.

Heavy feel or catching when turned by 
hand.

C

C

B

Cannot be turned by hand.

A

Excessively loose bearing.

C

C

B

C

Rotor shaft, oil return port (Check 
inside using penlight.)

Carbon or sludge deposits in oil drain 
port.

C

A

C

C

Boost control valve actuator oper-
ation (using a handy pump)

• Does not operate smoothly when air 

pressure is gradually applied.

• Stroke amount is not compliance 

with the air pressure.

A

A: 

Highly possible.

B: 

Possible.

C: 

May exist.

EM-36

< REMOVAL AND INSTALLATION >

[HRA2DDT]

TURBOCHARGER

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 failure:

INSPECTION AFTER INSTALLATION

Start engine and raise engine speed to check no exhaust emission leaks.

E1BIA1029ZZ

A.

Check for leakage

Suction side

: Between turbocharger and charge air cooler

Exhaust side

: Between turbocharger and outlet duct

EXHAUST MANIFOLD

EM-37

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EXHAUST MANIFOLD

Exploded View

INFOID:0000000010282217

Refer to 

GI-4, "Components"

 for symbols in the figure.

Removal and Installation

INFOID:0000000010282218

REMOVAL

NOTE:
• Exhaust manifold and turbocharger are assembled in one part. Refer to 

EM-33, "Removal and Installation"

for removal.

INSTALLATION

NOTE:
• Exhaust manifold and turbocharger are assembled in one part. Refer to 

EM-33, "Removal and Installation"

for installation.

Inspection

INFOID:0000000010282219

INSPECTION AFTER REMOVAL

NOTE:
• Exhaust manifold and turbocharger are assembled in one part. Refer to 

EM-33, "Removal and Installation"

for inspection.

E1BIA1010GB

1.

Cylinder head

2.

Exhaust manifold gasket 

3.

Exhaust manifold and turbocharg-
er assembly

4.

Exhaust manifold heat insulator

EM-38

< REMOVAL AND INSTALLATION >

[HRA2DDT]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

Exploded View

INFOID:0000000010287264

CAUTION:

Never remove or disassemble parts unless instructed as shown in the figure.

Refer to 

GI-4, "Components"

 for symbol marks in the figure.

Removal and Installation

INFOID:0000000010287265

REMOVAL

WARNING:

• Be sure to read 

FL-3, "General Precautions"

 when working on the high pressure fuel system.

• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO

2 

fire extinguisher.

• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
• To avoid the danger of being scalded, never drain engine coolant when engine is hot.

1.

Remove electric blow off valve. Refer to 

EM-27, "Removal and Installation"

.

2.

Release fuel pressure.

3.

Disconnect fuel feed hose quick connector with the following procedure. Disconnect fuel feed hose from
high pressure fuel pump.

1.

High pressure fuel pump

2.

High pressure fuel pipe

3.

High pressure fuel rail

4.

High pressure fuel pump O-ring

5.

High pressure fuel pump lifter

E1BIA1220GB

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

EM-39

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a.

Remove quick connector in the following procedures.

i.

Hold the connector while pushing tabs, and pull out the tube.

ii.

If quick connector sticks to high pressure fuel pump, push and
pull quick connectors several times until they start to move.
Then disconnect them by pulling.

CAUTION:

• Quick connector (1) can be disconnected when the tabs of

retainer (F) are depressed completely. Never twist it more
than necessary.

• Never use any tools to disconnected quick connector.
• Keep resin hose (C) away from heat. Be especially careful

when welding near the resin hose.

• Prevent acid liquid such as battery electrolyte, etc. from

getting on resin tube.

• Never bend or twist resin tube during installation and dis-

connection.

• Never remove the remaining retainer (2) on hard tube (or

the equivalent) (A) except when resin tube or retainer is
replaced.

• When resin tube or hard tube (or the equivalent) is

replaced, also replace retainer with new one.

• To prevent damage to each joint and protect it from the

entry of foreign matter, cover the joint with plastic bag (A)
or an equivalent.

4.

Disconnect high pressure fuel pump connector.

5.

Remove intake manifold. Refer to 

EM-25, "Removal and Installation"

.

6.

Remove high pressure fuel pipe using [SST: KV113E0010 (Mot.1566)].

7.

Remove high pressure fuel pump and lifter.

CAUTION:

To prevent damage to high pressure fuel pump and rocker cover, loosen high pressure fuel pump
bolts alternately by one turn at a time until the reaction force applied on the high pressure fuel
pump disappears.

INSTALLATION

A

:  Pull

B

: Push in tabs

JSBIA1689ZZ

B

: Connection (cross-section)

D

: To under floor fuel line

E

: To engine

G

: Disconnection

Retainer color

: Green

JPBIA0130ZZ

JPBIA0135ZZ

EM-40

< REMOVAL AND INSTALLATION >

[HRA2DDT]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

CAUTION:

• Do not reuse O-rings.
• To prevent damage to parts due to generated abnormal stress and eccentric load, always observe

the installation procedure.

1.

Install high pressure pump lifter in its housing.

2.

Install high pressure fuel pump according to the following procedure.

a.

Check that high pressure fuel pump lifter (1) is in low position.
NOTE:
If the high pressure fuel pump lifter is not in low position turn the
engine by hand until reach high pressure fuel pump lifter low
position.

b.

c.

Install O-ring to high pressure fuel pump. When handing new O-ring, paying attention to the following cau-
tion items:

CAUTION:

• Do not reuse O-ring.
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• Never damage O-ring with tools and fingernails during the installation. In addition, twisting or

stretching O-ring is not allowed. If O-ring is stretched during the installation to high pressure
fuel pump, never install high pressure fuel pump immediately.

d.

Install high pressure fuel pump lifter.

e.

Apply oil to the fitting area of O-ring and rocker cover side to install high pressure fuel pump.

CAUTION:

• Temporarily tighten bolt by hand. Alternately tighten bolt by one turn at a time until high pres-

sure fuel pump reaches rocker cover.

• After a pump flange sitting, tighten the bolts to the specified torque.

3.

Install the fuel tube, according to the following procedure using [SST: KV113E0010 (Mot.1566)].

CAUTION:

• When removing Fuel tube, always replace Fuel rail connector together with Fuel tube.
• Never reuse fuel tube.
• Never use fuel tube if its terminal tip is damaged.
• Observe the tightening order and the tightening torque.

a.

Temporarily tighten flare nut (A) and (B) of fuel tube (3) until
seated.

CAUTION:

When temporarily tightening flare nut, place pipe in the cen-
ter of the nut inner diameter.

b.

Tighten bolt (4).

c.

Tighten flare nut (A) and (B) in alphabetical order.

CAUTION:

Always fit the tool completely with the nut.

E1BIA1164ZZ

1

: High pressure fuel pump

2

: Fuel rail connector

E1BIA1165ZZ

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

EM-41

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[HRA2DDT]

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4.

Connect fuel feed hose with the following procedure, and them install the fuel feed hose.

a.

Check the connection for damage or any foreign materials.

b.

Align the connector with the tube, then insert the connector straight into the tube until a click sound is
heard.

c.

After connecting, check that the connection is secured with fol-
lowing procedures.
• Visually confirm that the two tabs are connected to the con-

nector.

• Pull (A) the tube and the connector to check that they are

securely connected.

CAUTION:

If retainer cannot be installed smoothly, quick connector
may be have not been installed correctly. Check connection
again.

5.

When replacing high pressure fuel pump, this procedure must be perform. Refer to 

ECH-102, "Special

Repair Requirement List"

6.

Install in the reverse order of removal after this step.

Inspection

INFOID:0000000010287266

INSPECTION AFTER INSTALLATION

Check for Fuel Leakage

1.

Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check that
there is no fuel leakage at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.

2.

Start the engine. With engine speed increased, check again that there is no fuel leakage at connection
points.

CAUTION:

Never touch the engine immediately after it is stopped because the engine is extremely hot.

JSBIA1692ZZ

EM-42

< REMOVAL AND INSTALLATION >

[HRA2DDT]

FUEL INJECTOR AND FUEL TUBE

FUEL INJECTOR AND FUEL TUBE

Exploded View

INFOID:0000000010282220

Refer to 

GI-4, "Components"

 for symbols in the figure.

CAUTION:

Never remove or disassemble parts unless instructed as shown in the figure.

Removal and Installation

INFOID:0000000010282221

WARNING:

• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO

2

 fire extinguisher. 

• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.

REMOVAL

Fuel injector and fuel tube removal.

1.

Release the fuel pressure. Refer to 

ECH-121, "Work Procedure"

.

2.

Remove blow off valve. Refer to 

EM-27, "Removal and Installation"

3.

Remove intake manifold. Refer to 

EM-25, "Exploded View"

.

4.

Remove high pressure fuel pipe. Refer to 

EM-38, "Exploded View"

5.

Unclip injection harness (1) from fuel tube.

1.

Fuel tube

2.

O-ring seal

3.

O-ring lower seal

4.

Ring stopper

5.

Holder

6.

Fuel Injector

7.

Seal ring

8.

Fuel pressure sensor

9.

Teflon ring seal

E1BIA1012GB

FUEL INJECTOR AND FUEL TUBE

EM-43

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[HRA2DDT]

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6.

Disconnect:
• Fuel injector connectors (2).
• Fuel pressure sensor connector (3) 

7.

Remove fuel tube and fuel injector assembly.

CAUTION:

• When removing, be careful to avoid any interference with fuel injector.
• Use a shop cloth to absorb any fuel leakage from fuel tube.
• Never reuse fuel tube.

8.

Remove fuel injector from fuel tube with the following procedure:

a.

Remove injector holder.

b.

Remove fuel injector by pulling straight.

CAUTION:

• Be careful with remaining fuel that may go out from fuel tube.
• Be careful not to damage fuel injector nozzle during removal.
• Never bump or drop fuel injector.

Fuel injector seal disassembly.

1.

Remove carefully from fuel injector:
• O-ring seal (1).
• O-ring lower seal (2).
• ring stopper (3).

CAUTION:

• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign

material.

• When installing O-ring, be careful not to scratch it with

tool or fingernails. Also be careful not to twist or stretch
O-ring. If O-ring is stretched while installing, never insert it quickly into fuel tube.

• Insert O-ring straight into fuel tube. Never decenter or twist it.

2.

Remove carefully from fuel injector teflon ring seal (4) following this procedure.
• Clean fuel injector

CAUTION:

It is forbidden to use a wire brush, sandpaper, etc.

• Cut fuel injector teflon ring seal with a pliers circlip.

CAUTION:

Take care to not damage fuel injector nozzle.

INSTALLATION

Fuel injector seal assembly.

E1BIA1166ZZ

E1BIA1167ZZ

EM-44

< REMOVAL AND INSTALLATION >

[HRA2DDT]

FUEL INJECTOR AND FUEL TUBE

1.

Install on fuel injector: 
• O-ring seal (1).
• O-ring lower seal (2).
• ring stopper (3).

CAUTION:

• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign

material.

• When installing O-ring, be careful not to scratch it with

tool or fingernails. Also be careful not to twist or stretch
O-ring. If O-ring is stretched while installing, never insert it quickly into fuel tube.

• Insert O-ring straight into fuel tube. Never decenter or twist it.

2.

Install carefully on fuel injector teflon ring seal (4) following this procedure using [SST: Mot.1533 (—)].
• Install on the fuel injector the cone (1) of [SST: Mot.1533 (—)]. 
• Install teflon ring seal on the cone (1) of [SST: Mot.1533 (—)].
• Push teflon ring seal into fuel injector groove.
• Remove the cone (1) of [SST: Mot.1533 (—)].

• Push the reforming tool (1) of [SST: Mot.1533 (—)] around fuel

injector nozzle to retract teflon ring seal during 30 secondes
minimum.
NOTE:
This operation is necessary to set correct outside diameter to
teflon ring seal.

Fuel injector and fuel tube installation.

CAUTION:

Never reuse fuel tube.

1.

Install fuel injector to fuel tube.

2.

Set fuel tube and fuel injector assembly at its position for installation on cylinder head.

CAUTION:

For installation, be careful not to interfere with fuel injector nozzle.

3.

Install fuel tube and injector assembly onto cylinder.
• Tighten mounting bolts.

4.

Connect harness connector to fuel injector.

5.

When replacing fuel injector, this procedure must be performed. Refer to 

ECH-102, "Special Repair

Requirement List"

.

6.

Install remaining parts in the reverse order of removal.

Inspection

INFOID:0000000010282222

INSPECTION AFTER INSTALLATION

E1BIA1167ZZ

E1BIA1168ZZ

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FUEL INJECTOR AND FUEL TUBE

EM-45

< REMOVAL AND INSTALLATION >

[HRA2DDT]

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Check on Fuel Leakage

1.

Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there
are no fuel leakage at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.

2.

Start the engine. With engine speed increased, check again that there are no fuel leakage at connection
points.

CAUTION:

Never touch the engine immediately after stopped, as the engine becomes extremely hot.

EM-46

< REMOVAL AND INSTALLATION >

[HRA2DDT]

OIL PAN (LOWER)

OIL PAN (LOWER)

Exploded View

INFOID:0000000010282223

Refer to 

GI-4, "Components"

 for symbol marks in the figure.

Removal and Installation

INFOID:0000000010282224

REMOVAL

1.

Drain engine oil. Refer to 

LU-9, "Draining"

.

2.

Remove oil pan (lower) with the following procedure:

1.

Dowel pin 

2.

Cylinder block

3.

Baffle plate

4.

Dowel pin

5.

Oil pan (upper)

6.

Oil pan (lower)

7.

Drain plug washer

8.

Drain plug 

E1BIA1015GB

OIL PAN (LOWER)

EM-47

< REMOVAL AND INSTALLATION >

[HRA2DDT]

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a.

Loosen mounting bolts in reverse order as shown in the figure.

b.

Insert seal cutter [SST: KV10111100] (A) between oil pan (upper)
and oil pan (lower).

CAUTION:

• Be careful not to damage the mating surface.
• Never insert a screwdriver. This damages the mating sur-

faces.

c.

Slide the seal cutter [SST: KV10111100] by tapping on the side
of tool with a hammer.

d.

Remove oil pan (lower).

INSTALLATION

1.

Install oil pan (lower) as follows:

a.

Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Also remove old liquid gasket from mating surface of oil pan

(upper).

• Remove old liquid gasket from the bolt holes and threads.

CAUTION:

Never scratch or damage the mating surface when cleaning
off old liquid gasket.

b.

Apply a continuous bead of liquid gasket (B) with a 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 liquid gas-
ket application.

: Engine front

E1BIA1041ZZ

JPBIA0276ZZ

JPBIA4745ZZ

a

: 7.5 - 9.5 mm (0.295 - 0.374 in)

c

: 

φ

4.0 - 5.0 mm (0.157 - 0.197 in)

1

: Oil pan (lower)

: Engine outside

E1BIA1040ZZ

EM-48

< REMOVAL AND INSTALLATION >

[HRA2DDT]

OIL PAN (LOWER)

c.

Tighten bolts in numerical order as shown in the figure. 

2.

Install oil pan drain plug.
• Refer to the figure of components of former page for installation direction of drain plug washer. Refer to

EM-46, "Exploded View"

.

3.

Install in the reverse order of removal after this step.
NOTE:
Wait at last 30 minutes after oil pan (lower) is installed before pouring engine oil.

Inspection

INFOID:0000000010282225

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 

LU-8, "Inspection"

.

2.

Start engine, and check there is no leakage of engine oil.

3.

Stop engine and wait for 10 minutes.

4.

Check the engine oil level again. Refer to 

LU-9, "Refilling"

.

: Engine front

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