Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD) - part 19

EXHAUST MANIFOLD

EM-289

< REMOVAL AND INSTALLATION >

[K9K]

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EXHAUST MANIFOLD

Exploded View

INFOID:0000000010287205

Refer to 

GI-4, "Components"

 for symbol marks in the figure.

Removal and Installation

INFOID:0000000010282072

REMOVAL

1.

Remove turbocharger assembly. Refer to 

EM-287, "Removal and Installation"

.

2.

Loosen exhaust manifold mounting nuts in the reverse order as
shown. Then remove exhaust manifold.

CAUTION:

Be careful not to deform each turbocharger piping when pulling
out the assembly.

INSTALLATION

1.

Clean the surface of exhaust manifold and cylinder head.

2.

Install new gasket to cylinder head.

1.

Gasket 

2.

Exhaust manifold

3.

Exhaust gas temperature sensor 1

4.

Exhaust gas pressure sensor 1

5.

Gasket

A.

To high pressure EGR pipe

E1BIA0886GB

JPBIA3039ZZ

EM-290

< REMOVAL AND INSTALLATION >

[K9K]

EXHAUST MANIFOLD

3.

Tighten the mounting nuts in numerical order as shown.

4.

Install in reverse order of removal after this step.

Inspection

INFOID:0000000010287206

INSPECTION AFTER INSTALLATION

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

: 26.0 N·m (2.7 kg-m, 19 ft-lb)

JPBIA3039ZZ

GLOW PLUG

EM-291

< REMOVAL AND INSTALLATION >

[K9K]

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GLOW PLUG

Exploded View

INFOID:0000000010282074

Removal and Installation

INFOID:0000000010282075

REMOVAL

CAUTION:

Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.

1.

Disconnect battery ground cable.

2.

Remove engine cover. Refer to 

EM-281, "Removal and Installation"

.

3.

Disconnect harness connector from glow plug.

4.

Remove glow plug.

CAUTION:

• When removing or installing, do not use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from

height of 10 cm (3.94 in) or higher, always replace it.]

INSTALLATION

1.

Remove adhered carbon from glow plug installation hole with a reamer.

2.

Install glow plug.

3.

Install remaining parts in reverse order of removal.

JPBIA3124GB

1.

Glow plug

Engine front

 : N·m (kg-m, ft-lb)

: 15.0 N·m (1.5 kg-m, 11 ft-lb)

EM-292

< REMOVAL AND INSTALLATION >

[K9K]

VACUUM PUMP

VACUUM PUMP

Exploded View

INFOID:0000000010287207

Refert to 

GI-4, "Components"

 For symbol marks in the figure.

Removal and Installation

INFOID:0000000010287208

REMOVAL

1.

Remove air cleaner case. Refer to 

EM-279, "Exploded View"

.

2.

Disconnect vacuum hose from vacuum pump side.

3.

Remove vacuum pump bracket.

4.

Remove vacuum pump.

INSTALLATION

Install in the reverse order of removal.

Inspection

INFOID:0000000010287209

INSPECTION BEFORE REMOVAL

1.

Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
• Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connec-

tor.

2.

Start engine and measure generated vacuum at idle speed.

E1BIA0905GB

1.

Vacuum pump

2.

Gasket

3.

Vacuum pump  bracket

A.

To electric throttle control actuator

B.

To brake booster

C.

To turbocharger boost control sole-
noide valve.

Standard

: -86.6 to -101.3 kPa (-866 to -1,013 mbar, -650 to -760 mmHg, -25.59 to -29.92 inHg)

INJECTION TUBE AND FUEL INJECTOR

EM-293

< REMOVAL AND INSTALLATION >

[K9K]

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INJECTION TUBE AND FUEL INJECTOR

Exploded View

INFOID:0000000010287210

Refer to 

GI-4, "Components"

 for symbol marks in the figure.

Removal and Installation

INFOID:0000000010287211

REMOVAL

CAUTION:

• Be sure to read “Precautions for Diesel Equipment”. Refer to 

FL-30, "General Precautions"

.

• 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 injector. If you open an injector by mistake, you will have to change it.

This is because of the manufacturing and installation tolerances and because there is a risk of con-
taminating the inside of the injector.

• The rod filter of the injector must not be removed.
NOTE:
It is possible to replace a single injection tube.

1.

Disconnect the battery cable from negative terminal.

2.

Remove air inlet tube and air inlet hose. Refer to 

EM-281, "Exploded View"

.

3.

Remove oil level gauge guide and plug the hole.

4.

Remove injection tube protection cover.

5.

Remove the neck located on the fuel rail,

1.

Spill hose

2.

Injection tube

3.

Fuel injector

4.

Heat protection washer

5.

Fuel injector bracket

6.

Fuel injector bracket spacer

7.

Fuel rail stud bolt

8.

Fuel rail

9.

High pressure protection cover (low-
er)

10. Injection tube

11.

High pressure supply pump

12. High pressure protection cover (up-

per)

13. Oil level gauge guide

E1BIA0907GB

EM-294

< REMOVAL AND INSTALLATION >

[K9K]

INJECTION TUBE AND FUEL INJECTOR

NOTE:
Undo the nut on the pump side or the injector side, then the nut located on the rail side. Undo the
nuts for each pipe in turn. Move the nut along the pipe keeping the olive in contact with the taper.

6.

Remove all the injection tubes.

7.

Plug all the holes in the injection circuit.

8.

Remove fuel rail.

9.

Disconnect fuel return pipe.

10. Manually remove the injector diesel return hose.

CAUTION:

Never force on the diesel injector return hose

11. Plug all the holes of the injection circuit.

12. Disconnect the injector harness connector.
13. Unscrew the injector bracket.

14. Remove the injector.

15. Pull off the flame shield washer.

INSTALLATION

CAUTION:

All the injection tubes removed must be systematically replaced.
1.

Clean the injector sockets and the injector bodies, as well as their brackets using a lint-free cloth (use the
wipes recommended for this purpose, dipped in clean solvent.

2.

Dry off using a different new wipe.

3.

Insert a large diameter screwdriver (diameter > 8 mm (0.315 in)into the well to block the opening to the
combusion chamber. 

4.

Blast out any scale residue in the well using a compressed air nozzle.

5.

Remove the screwdriver and repeat the cleaning operation for the injector well concerned twice in succes-
sion.

6.

Replace the flame shield washer with a new one.

7.

Position the injector.

8.

Tighten its mounting bracket.

9.

Install injection tubes with new one.

10. Finger tightens the nuts.
11. Before fitting the new injection tubes, lightly lubricate the nut threads with the oil from the sachet provided

in the new parts kit.
NOTE:
Fit the pump/rail pipe before the rail/injector tubes.

12. Fit the pump-rail injection tube as follow:

• Remove the protective plugs from the high pressure pump outlet, the high pressure rail inlet and the

pipe.

• 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.
• Finger tighten the nuts of the injection tube starting with the one located on the rail side.

13. Install the rail-injector injection tube.

14. Tighten the injection tube nut.

15. Connect fuel return pipe.

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

ECK-130, "Special Repair

Requirement List"

.

17. Install in the reverse order to removal for the other refitting operations.

: 27.0 N·m (2.8 kg-m, 20 ft-lb)

: 28.0 N·m (2.9 kg-m, 21 ft-lb)

INJECTION TUBE AND FUEL INJECTOR

EM-295

< REMOVAL AND INSTALLATION >

[K9K]

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Inspection

INFOID:0000000010287267

INSPECTION AFTER INSTALLATION

• 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.

• 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 

FL-30, "General Precautions"

.

E1BIA0649ZZ

EM-296

< REMOVAL AND INSTALLATION >

[K9K]

OIL PAN

OIL PAN

Exploded View

INFOID:0000000010287212

Refer to 

GI-4, "Components"

 for symbol marks in the figure.

Removal and Installation

INFOID:0000000010287213

REMOVAL

CAUTION:

Never drain engine oil when the engine is hot to avoid the danger of being scalded.

1.

Remove RH front wheel. Refer to 

WT-60, "Removal and Installation"

. (with TPMS) or 

WT-73, "Removal

and Installation"

 (without TPMS).

2.

Remove fender protector RH. Refer to 

EXT-32, "Removal and Installation"

.

3.

Remove engine mounting bracket. Refer to 

EM-318, "Exploded View"

.

4.

Remove center bearing bracket as shown.

JPBIA3125GB

1.

Baffle plate

2.

Gasket

3.

Oil pan

4.

O-ring

5.

Drain plug

6.

Oil level gauge guide

7.

Transaxle

8.

Crankshaft position sensor (POS)

MBIB1037E

OIL PAN

EM-297

< REMOVAL AND INSTALLATION >

[K9K]

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5.

Remove A/C compressor bracket mounting bolt as shown.

6.

Remove oil level gauge guide.

7.

Drain engine oil. Refer to 

LU-36, "Draining"

.

CAUTION:

Perform when engine is cold.

8.

Remove oil pan and transaxle joint bolts.

9.

Support the engine bottom of the oil pan with a transmission jack
etc.

10. Remove oil pan bolt reverse order as shown.

MBIB1038E

MBIB1039E

MBIB0575E

MBIB1257E

EM-298

< REMOVAL AND INSTALLATION >

[K9K]

OIL PAN

• Insert seal cutter (special service tool) between upper oil pan

and cylinder block. Slide tool by tapping on the side of the tool
with a hammer.

CAUTION:

Exercise care never damage mating surface.

11. Remove oil pan and baffle plate.

INSTALLATION

• Install in the reverse order of removal paying attention to the following.

1.

Apply liquid gasket as shown.
• Use Genuine Liquid Gasket or equivalent.

2.

Install baffle plate.

3.

Install oil pan.
• Tighten the mounting bolts of oil pan on the clutch housing without locking.
• Tighten the bolts in the numerical order shown in the figure.

• Tighten the mounting bolts of oil pan on the clutch housing.

4.

At least 30 minutes after oil pan is installed, pour engine oil.

SEM365EA

MBIB0593E

MBIB0594E

: 14 N·m (1.4 kg-m, 10 ft-lb)

MBIB1257E

: 44 N·m (4.5 kg-m, 10 ft-lb)

OIL PAN

EM-299

< REMOVAL AND INSTALLATION >

[K9K]

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Inspection

INFOID:0000000010287214

INSPECTION AFTER REMOVAL

Clean oil pump assembly if any object attached.

INSPECTION AFTER INSTALLATION

• Inspection the engine oil level. Refer to 

LU-35, "Inspection"

.

• Start the engine, and make sure there is no leak of engine oil. Refer to 

LU-35, "Inspection"

.

EM-300

< REMOVAL AND INSTALLATION >

[K9K]

HIGH PRESSURE SUPPLY PUMP

HIGH PRESSURE SUPPLY PUMP

Exploded View

INFOID:0000000010287215

Refer to 

GI-4, "Components"

 for symbol marks in the figure.

Removal and Installation

INFOID:0000000010287216

REMOVAL

CAUTION:

• Be sure to read “Precautions for Diesel Equipment”. Refer to 

FL-30, "General Precautions"

.

• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.

1.

Disconnect the battery cable from the negative terminal.

2.

Remove air inlet hose. Refer to 

EM-281, "Exploded View"

.

3.

Remove the timing belt. Refer to 

EM-305, "Exploded View"

.

4.

Remove the neck located on the fuel rail.

5.

Remove the oil level gauge guide and plug the hole. 

6.

Remove high pressure protection cover. Refer to 

EM-293, "Exploded View"

.

7.

Carefully disconnect:
• The connectors from the flow actuator,
• The connectors from the fuel temperature sensor,
• On the pump, the fuel supply and return pipes.
• The return pipe connecting the injectors with the pump.

8.

Remove the injection tube connecting the pump to the rail. Refer to 

EM-293, "Exploded View"

.

9.

Plug all the holes of the injection circuit.

10. Remove the three mounting bolts from the high pressure supply pump then remove it.

1.

Cylinder head

2.

High pressure supply pump sprocket 3.

High pressure supply pump

4.

High pressure supply pump protector

E1BIA0885GB

HIGH PRESSURE SUPPLY PUMP

EM-301

< REMOVAL AND INSTALLATION >

[K9K]

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11. In case of high pressure supply pump replacement:

• Install the high pressure supply pump in a vice with jaws.
• Immobilise  the high pressure supply pump sprocket with a off-

set spanner (1).

• Remove  the high pressure supply pump sprocket nut (2).

• Remove the end piece (1) of the tool [SST: — (Mot.1525)] by

unscrewing the bolt (2). 

• Protect the contact areas between the tool [SST: —

(Mot.1525)] equipped with the tool [SST: — (Mot.1525-02)]
and the high pressure supply pump sprocket. 

• Fit the tool [SST: — (Mot.1525)] equipped with the tool [SST:

— (Mot.1525-02)] to remove the high pressure supply pump
sprocket. 

• Remove the high pressure supply pump sprocket.

INSTALLATION

1.

In case of high pressure supply pump replacement:
• Install the high pressure supply pump sprocket. 
• Torque tighten the high pressure supply pump sprocket.

2.

Install the pump then position the mounting bolts without tightening them.

3.

Before fitting the new injection tube, lightly lubricate the nut threads with the oil from the sachet provided
in the new parts kit.

4.

Refit the injection tube, to do this:
• remove the protective plugs,
• 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.

5.

Finger tighten the nuts of the injection tube starting with the one located on the rail side.

6.

Tighten the mounting bolts on the high pressure pump.

7.

Tighten the injection tube nut.

8.

Refit high pressure supply pump protector.

E1BIA0909ZZ

E1BIA0910ZZ

: 70.0 N·m (7.1 kg-m, 52 ft-lb)

MBIB9036E

: 23.0 N·m (2.3 kg-m, 17 ft-lb)

: 28.0 N·m (2.9 kg-m, 21 ft-lb)

EM-302

< REMOVAL AND INSTALLATION >

[K9K]

HIGH PRESSURE SUPPLY PUMP

9.

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

ECK-130, "Spe-

cial Repair Requirement List"

.

10. Refit in the reverse order to removal for the other refitting operations.

11. Test the sealing of the high pressure after it has been repaired (refer to “SPECIAL FEATURES” in 

EM-

263, "Precaution for Diesel Equipment"

).

ROCKER COVER

EM-303

< REMOVAL AND INSTALLATION >

[K9K]

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ROCKER COVER

Exploded View

INFOID:0000000010287217

Refer to 

GI-4, "Components"

 for symbol marks in the figure.

Removal and Installation

INFOID:0000000010287218

REMOVAL

1.

Remove air cleaner case. Refer to 

EM-279, "Exploded View"

.

2.

Remove inlet tube and air inlet hose. Refer to 

EM-281, "Exploded View"

.

3.

Remove high pressure protection cover (upper). Refer to 

EM-293, "Exploded View"

.

4.

Remove electric throttle control actuator.

5.

Remove fuel injector. Refer to 

EM-293, "Exploded View"

.

6.

Remove rocker cover.
• Loosen holding bolts in the reverse order as shown in the fig-

ure and remove.

INSTALLATION

E1BIA0908GB

1.

Blow-by hose

2.

Rocker cover

3.

Gasket

4.

Camshaft position sensor

5.

O-ring

A.

 To turbocharger air inlet pipe

: Engine front

JPBIA3119ZZ

EM-304

< REMOVAL AND INSTALLATION >

[K9K]

ROCKER COVER

1.

Apply liquid gasket on locations shown in the figure. 
• Use Genuine Liquid gasket or equivalent.

2.

Tighten holding bolts in the numerical order as shown in the fig-
ure. 

3.

Install in the reverse order of removal after this steps.

MBIB0581E

: Engine front

: 12 N·m (1.2 kg-m, 9 ft-lb)

JPBIA3119ZZ