Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD) - part 14

 

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Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD) - part 14

 

 

CYLINDER HEAD

EM-209

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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Removal and Installation

INFOID:0000000010715509

REMOVAL

1.

Release fuel pressure. Refer to 

ECM-135, "Work Procedure"

.

2.

Drain engine coolant and engine oil. Refer to 

CO-38, "Draining"

 and 

LU-23, "Draining"

.

3.

Remove the following components and related parts.
• Intake manifold: Refer to 

EM-149, "Exploded View"

.

• Exhaust manifold: Refer to 

EM-153, "Exploded View"

.

• High pressure fuel pump: Refer to 

EM-159, "Exploded View"

.

• Fuel tube and fuel injector assembly: Refer to 

EM-164, "Exploded View"

.

• Water outlet: Refer to 

CO-53, "Exploded View"

.

• Rocker cover: Refer to 

EM-170, "Exploded View"

.

• Front cover, timing chain: Refer to 

EM-183, "Exploded View"

.

Valve collet

Valve spring retainer

Valve spring 
(with valve spring seat) (EXH)

Valve oil seal

Valve guide (EXH)

Valve seat (EXH)

Valve (EXH)

Valve (INT)

Valve seat (INT)

Cylinder head

Valve guide (INT)

Spark plug

Valve spring 
(with valve spring seat) (INT)

Comply with the installation procedure 
when tightening. Refer to 

EM-210

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

: Should be lubricated with oil.

JPBIA1753GB

EM-210

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER HEAD

• Camshaft: Refer to 

EM-196, "Exploded View"

.

4.

Remove cylinder head.
• Loosen cylinder head bolts in the order from 10 to 1 as shown

in the figure. 

• Using TORX socket (size: E18), loosen cylinder head bolts.

5.

Remove cylinder head gasket.

INSTALLATION

1.

Install cylinder head gasket.

2.

Install cylinder head, and tighten cylinder head bolts in the order
from 1 to 10 as shown in the figure with the following procedure.

CAUTION:

If cylinder head bolts are reused, check their outer diame-
ters before installation. Refer to 

EM-215, "Inspection"

.

a.

Apply new engine oil to threads and seating surface of mounting
bolts.

b.

Tighten all cylinder head bolts.

c.

Turn all cylinder head bolts 100 degrees clockwise (angle tightening).

CAUTION:

Check and confirm the tightening angle by using an angle
wrench [SST: KV10112100] 

 or protractor. Never judge by

visual inspection without the tool.

d.

Completely loosen.

CAUTION:

In this step, loosen cylinder head bolts in reverse order that
indicated in the figure.

e.

Tighten all cylinder head bolts.

f.

Turn all cylinder head bolts 95 degrees clockwise (angle tightening).

g.

Turn all cylinder head bolts 95 degrees clockwise again (angle tightening).

3.

Install in the reverse order of removal, for the rest of parts. 

Disassembly and Assembly

INFOID:0000000010715510

DISASSEMBLY

1.

Remove spark plug with spark plug wrench (commercial service tool).

2.

Remove valve lifter.
• Identify installation positions, and store them without mixing them up.

: Engine front

PBIC3206J

: Engine front

: 40.0 N·m (4.1 kg-m, 30 ft-lb)

: 0 N·m (0 kg-m, 0 ft-lb)

: 40.0 N·m (4.1 kg-m, 30 ft-lb)

PBIC3206J

PBIC3208J

CYLINDER HEAD

EM-211

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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3.

Remove valve collet. 
• Compress valve spring with the valve spring compressor [SST:

KV10116200] (A), the attachment [SST: KV10115900] (C), and
the adapter [SST: KV10109220] (B). Remove valve collet with
a magnet hand.

CAUTION:

• Be careful not to damage valve lifter holes.
• Fit the attachment [SST: KV10115900 (J-26336-20)] 

 in

thecenter of valve spring retainer 

 to press it.

4.

Remove valve spring retainer and valve spring (with valve spring seat).

CAUTION:

Never remove valve spring seat from valve spring.

5.

Push valve stem to combustion chamber side, and remove valve. 
• Identify installation positions, and store them without mixing them up.

6.

Remove valve oil seal with a valve oil seal puller [SST:
KV10107902] .

7.

When valve seat must be replaced.
• Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat

recess in cylinder head. Set the machine depth stop to ensure this. Refer to 

EM-251, "Cylinder Head"

.

CAUTION:

Never bore excessively to prevent cylinder head from scratching.

8.

When valve guide must be replaced.

JPBIA0180ZZ

JPBIA4477ZZ

PBIC3210J

EM-212

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER HEAD

a.

To remove valve guide, heat cylinder head to 110 to 130

°

C (230

to 266

°

F) by soaking in heated oil 

.

b.

Drive out valve guide with a hammer and valve guide drift (com-
mercial service tool) (A).

CAUTION:

Cylinder head contains heat, wear protective equipment to
avoid getting burned.

ASSEMBLY

1.

When valve guide is removed, install it. 

CAUTION:

Replace with oversize [0.2 mm (0.008 in)] valve guide.

a.

Ream cylinder head valve guide hole with a valve guide reamer
(commercial service tool) (A).

b.

Heat cylinder head to 110 to 130

°

C (230 to 266

°

F) by soaking in

heated oil 

.

PBIC3214J

JSBIA2470ZZ

For service parts: Oversize [0.2 mm (0.008 in)] 

Refer to 

EM-251, "Cylinder Head"

.

JPBIA0185ZZ

PBIC3214J

CYLINDER HEAD

EM-213

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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c.

Press valve guide 

 from camshaft side to dimensions as

shown in the figure.

CAUTION:

Cylinder head contains heat, wear protective equipment to
avoid getting burned.

d.

Apply reamer finish to valve guide with a valve guide reamer
(commercial service tool) (A).

2.

When valve seat is removed, install it. 

CAUTION:

Replace with oversize [0.5 mm (0.020 in)] valve seat.

a.

Ream cylinder head 

 recess diameter for service valve seat

.

• Be sure to ream in circles concentric to the valve guide center.

This will enable valve seat to fit correctly.

b.

Heat cylinder head to 110 to 130

°

C (230 to 266

°

F) by soaking in

heated oil 

.

c.

Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head.

CAUTION:

• Never touch cold valve seats directly.
• Cylinder head contains heat, wear protective equipment to avoid getting burned.

: Cylinder head

Projection (H)

: Refer to 

EM-251, "Cylinder Head"

.

PBIC3217J

Standard

: Refer to 

EM-251, "Cylinder Head"

.

JPBIA0185ZZ

For service parts: Oversize [0.5 mm (0.020 in)]

Refer to 

EM-251, "Cylinder Head"

.

PBIC3218J

PBIC3214J

EM-214

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER HEAD

d.

Using valve seat cutter set (commercial service tool) (A) or valve
seat grinder, finish valve seat to the specified dimensions. For
dimensions, refer to 

EM-251, "Cylinder Head"

.

CAUTION:

When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat. 

e.

Using compound, grind to adjust valve fitting. 

f.

Check again for normal contact. Refer to 

EM-215, "Inspection"

.

3.

Install valve oil seal.
• Install with a valve oil seal drift [SST: KV10115600] 

 to match

dimension in the figure.
NOTE:
Dimension is height that measured before installing valve
spring (with valve spring seat).

4.

Install valve.
• Install larger diameter to intake side.

5.

Install valve spring (with valve spring seat).
• Install smaller pitch (valve spring seat side) to cylinder head

side .

• Confirm identification color 

 of valve spring.

6.

Install valve spring retainer.

7.

Install valve collet.
• Compress valve spring with the valve spring compressor [SST:

KV10116200] (A), the attachment [SST: KV10115900] (C), and
the adapter [SST: KV10109220] (B). Install valve collet with a
magnet hand.

CAUTION:

• Be careful not to damage valve lifter holes.

JSBIA2471ZZ

Height (H)

: 15.1 - 15.7 mm (0.594 - 0.618 in)

PBIC3211J

: Valve spring seat (Do not remove from valve spring.)

Intake

: White

Exhaust

: Orange

JPBIA4479ZZ

JPBIA0180ZZ

CYLINDER HEAD

EM-215

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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• Fit the attachment [SST: KV10115900 (J-26336-20)] 

 in

thecenter of valve spring retainer 

 to press it.

• Tap valve stem edge lightly with a plastic hammer after instal-

lation to check its installed condition.

8.

Install valve lifter.
• Install it in the original position.

9.

Install spark plug with spark plug wrench (commercial service tool).

Inspection

INFOID:0000000010715511

INSPECTION AFTER REMOVAL

Cylinder Head Bolts Outer Diameter

• Cylinder head bolts are tightened by plastic zone tightening

method. Whenever the size difference between (d1) and (d2)
exceeds the limit, replace them with a new one. 

• If reduction of outer diameter appears in a position other than (d2),

use it as (d2) point.

Cylinder Head Distortion

NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to 

EM-231, "Inspec-

tion"

.

1.

Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.

CAUTION:

Never allow gasket debris to enter passages for engine oil or water.

2.

At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions using straightedge (A)
and feeler gauge (B).

• If it exceeds the limit, replace cylinder head.

INSPECTION AFTER DISASSEMBLY

VALVE DIMENSIONS

• Check the dimensions of each valve. For the dimensions, refer to 

EM-251, "Cylinder Head"

.

• If dimensions are out of the standard, replace valve and check valve seat contact. Refer to "VALVE SEAT

CONTACT".

VALVE GUIDE CLEARANCE

JPBIA4477ZZ

Limit [(d1) – (d2)]: 0.15 mm (0.0059 in)

PBIC3994E

Limit: Refer to 

EM-251, "Cylinder Head"

.

JSBIA2474ZZ

EM-216

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER HEAD

Valve Stem Diameter

• Measure the diameter of valve stem with micrometer (B).

Valve Guide Inner Diameter

• Measure the inner diameter of valve guide with bore gauge (A).

Valve Guide Clearance

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve

stem diameter)

• If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be

replaced. Refer to 

EM-210, "Disassembly and Assembly"

.

VALVE SEAT CONTACT

• After confirming that the dimensions of valve guides and valves are within the specifications, perform this

procedure.

• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve

contact on the surface.

• Check if the contact area band is continuous all around the circum-

ference.

• If not, grind to adjust valve fitting and check again. If the contacting

surface still has “NG” conditions 

 even after the recheck, replace

valve seat. Refer to 

EM-210, "Disassembly and Assembly"

.

VALVE SPRING SQUARENESS

• Set a try square (A) along the side of valve spring and rotate

spring. Measure the maximum clearance 

 between the top of

spring and try square.

• If it exceeds the limit, replace valve spring.

VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

• Check valve spring pressure with valve spring seat installed at the

specified spring height.

CAUTION:

Never remove valve spring seat from valve spring.

• If the installation load or load with valve open is out of the stan-

dard, replace valve spring (with valve spring seat).

Standard: Refer to 

EM-251, "Cylinder Head"

.

Standard: Refer to 

EM-251, "Cylinder Head"

.

Standard and Limit: Refer to 

EM-251, "Cylinder Head"

.

JSBIA2475ZZ

: OK

JPBIA0187ZZ

: Contact

C

:  V-block

Limit

: Refer to 

EM-251, "Cylinder Head"

.

JSBIA4163ZZ

Standard

: Refer to 

EM-251, "Cylinder Head"

.

SEM113

CYLINDER HEAD

EM-217

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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INSPECTION AFTER INSTALLATION

Inspection for Leakage

The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required

quantity, fill to the specified level. Refer to 

MA-59, "Fluids and Lubricants"

.

• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-

age at connection points.

- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including

engine oil and engine coolant.

• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the

specified level, if necessary.

Summary of the inspection items:

*: Power steering fluid, brake fluid, etc.

Items

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Transmission / 
transaxle fluid

AT & CVT Models

Leakage

Level / Leakage

Leakage

MT Models

Level / Leakage

Leakage

Level / Leakage

Other oils and fluids*

Level

Leakage

Level

Fuel

Leakage

Leakage

Leakage

Exhaust gases

Leakage

E M - 2 1 8

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

OIL PAN (UPPER)

OIL PAN (UPPER)

Exploded View

INFOID:0000000010715512

Removal and Installation

INFOID:0000000010715513

REMOVAL

1.

Remove oil pan (lower). Refer to 

EM-156, "Exploded View"

.

2.

Remove oil filter. Refer to 

LU-25, "Removal and Installation"

.

3.

Remove water hoses of oil cooler.

4.

Remove oil level gauge and oil level gauge guide.

5.

Remove front cover, timing chain, balancer unit timing chain, and other related parts. Refer to 

EM-183,

"Exploded View"

.

Rear oil seal

O-ring

Oil pan (upper)

Drain plug

Drain plug washer

Oil pan (lower)

O-ring

Oil level gauge guide

Oil level gauge

To oil cooler

Oil pan (lower) side

: Oil pan side

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

: Should be lubricated with oil.

: Sealing point

JPBIA6893GB

OIL PAN (UPPER)

EM-219

< UNIT DISASSEMBLY AND ASSEMBLY >

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6.

Remove oil pan (upper) with the following procedure:

a.

Loosen bolts in the order from 10 to 1 as shown in the figure.

b.

Insert a screwdriver shown by the arrow (

) in the figure and

open up a crack between oil pan (upper) and cylinder block.

CAUTION:

A more adhesive liquid gasket is applied compared to previ-
ous types when shipped, so it should not be forced off the
position not specified.

c.

Insert seal cutter [SST: KV10111100] between oil pan (upper) and cylinder block, and slide it by tapping on
the side of the tool with a hammer.

CAUTION:

Be careful not to damage the mating surface.

7.

Remove O-ring between cylinder block and oil pan (upper).

8.

Remove rear oil seal. Refer to 

EM-206, "REAR OIL SEAL : Removal and Installation"

.

9.

Remove oil tempareture sensor, if necessary.

10. Remove oil cooler, if necessary.Refer to 

LU-26, "Exploded View"

.

INSTALLATION

CAUTION:

Do not reuse O-rings.

1.

Install oil pan (upper) with the following procedure:

a.

Use a scraper 

 to remove old liquid gasket from mating sur-

faces.
• Remove the old liquid gasket from mating surface of cylinder

block.

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

CAUTION:

Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket.

: Engine front

JPBIA5158ZZ

: Engine front

JPBIA5159ZZ

PBIC3949E

EM-220

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

OIL PAN (UPPER)

b.

Apply a continuous bead of liquid gasket 

 with a tube presser

(commercial service tool) as shown in the figure.

Use Genuine Liquid Gasket (Three Bond 1217H) or equiva-
lent.

CAUTION:

• Apply liquid gasket to outside of bolt hole for the posi-

tions shown by   marks.

• Attaching should be done within 5 minutes after liquid

gasket application.

c.

Install new O-ring at cylinder block side.

CAUTION:

Install avoiding misalignment of O-ring.

d.

Tighten bolts in the order from 1 to 10 as shown in the figure.

2.

Install rear oil seal with the following procedure.

CAUTION:

• The installation of rear oil seal should be completed within 5 minutes after installing oil pan

(upper).

• Always replace rear oil seal with new one.
• Never touch oil seal lip.

a.

Wipe off liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using a scraper.

b.

Apply engine oil to entire outside area of rear oil seal.

c.

Press-fit the rear oil seal using a suitable drift 

 with outer diam-

eter 115 mm (4.53 in) and inner diameter 90 mm (3.54 in).

: Oil pan (upper)

: 2 mm (0.08 in) protruded to outside

: 2 mm (0.08 in) protruded to rear oil seal mounting side

: 6.5 mm (0.26 in)

φ

4.0 - 5.0 (0.157 - 0.197 in)

: Engine front

: Engine outside

JPBIA5160ZZ

: Engine front

JPBIA5158ZZ

PBIC3951E

OIL PAN (UPPER)

EM-221

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

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• Press-fit to the specified dimensions as shown in the figure.

CAUTION:

• Never touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting part of

oil pan (upper) and cylinder block or the crankshaft.

• Press-fit straight, checking that rear oil seal does not curl

or tilt.

NOTE:
The standard surface of the dimension is the rear end surface of cylinder block.

3.

Install in the reverse order of removal, for the rest of parts. 

Inspection

INFOID:0000000010715514

INSPECTION AFTER REMOVAL

Clean oil strainer portion (part of the oil pump) if any object attached.

: Rear oil seal

: Cylinder block rear end surface

: 0 - 0.5 mm (0 - 0.020 in)

JPBIA3011ZZ

EM-222

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER BLOCK

CYLINDER BLOCK

Exploded View

INFOID:0000000010715515

Cylinder block

O-ring

Crankshaft position sensor (POS)

Crankshaft position sensor (POS) cover

Oil filter (for intake valve timing control)

Knock sensor 

JPBIA6819GB

CYLINDER BLOCK

EM-223

< UNIT DISASSEMBLY AND ASSEMBLY >

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Disassembly and Assembly

INFOID:0000000010715516

DISASSEMBLY

1.

Remove oil pan (upper). Refer to 

EM-218, "Exploded View"

.

2.

Remove thermostat housing. Refer to 

CO-51, "Exploded View"

.

3.

Remove knock sensor.

CAUTION:

Handle it carefully and avoid impacts.

4.

Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).

CAUTION:

• Handle crankshaft position sensor (POS) carefully and avoid impacts.
• Never disassemble.
• Never place crankshaft position sensor (POS) in a location where it is exposed to magnetism.

5.

Remove oil filter (for intake valve timing control).

6.

Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to

EM-102, "Inspection"

.

a.

Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. 

b.

Remove connecting rod cap. 

c.

Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side. 

CAUTION:

• Be careful not to damage matching surface with connect-

ing rod cap.

• Be careful not to damage the cylinder wall and crankshaft

pin, resulting from an interference of the connecting rod
big end.

7.

Remove connecting rod bearings. 

CAUTION:

When removing them, note the installation position. Keep them in the correct.

Oil pressure switch

Oil tempareture sensor

Oil jet

Top ring

Second ring

Oil ring

Snap ring

Piston

Piston pin

Connecting rod

Thrust bearing

Connecting rod bearing (upper)

Main bearing (upper)

Crankshaft key

Main bearing (lower)

Connecting rod bearing (lower)

Connecting rod cap

Connecting rod cap bolt

Main bearing cap

Main bearing cap bolt

Crankshaft

Signal plate

Rear oil seal

Comply with the installation procedure 
when tightening. Refer to 

EM-223

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Sealing point

: Should be lubricated with oil.

: Select with proper thickness.

PBIC0259E

EM-224

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR20DD]

CYLINDER BLOCK

8.

Remove piston rings form piston. 
• Before removing piston rings, check the piston ring side clearance. Refer to 

EM-102, "Inspection"

.

• Use a piston ring expander (commercial service tool) (A).

CAUTION:

• When removing piston rings, be careful not to damage

the piston.

• Be careful not to damage piston rings by expanding

them excessively.

9.

Remove piston from connecting rod with the following procedure: 

a.

Using snap ring pliers (A), remove snap rings.

b.

Heat piston to 60 to 70

°

C (140 to 158

°

F) with an industrial use

drier (A) or equivalent.

c.

Push out piston pin with stick (A) of outer diameter approxi-
mately 18 mm (0.71 in).

10. Remove main bearing cap bolts.

• Measure crankshaft end play before loosening main bearing cap bolts. Refer to 

EM-231, "Inspection"

.

JSBIA2493ZZ

JSBIA2494ZZ

JSBIA2495ZZ

JSBIA2496ZZ

 

 

 

 

 

 

 

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