Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD) - part 25

EGR SYSTEM

EM-385

< REMOVAL AND INSTALLATION >

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EGR SYSTEM

Exploded View

INFOID:0000000010281977

Removal and Installation

INFOID:0000000010281978

REMOVAL

1.

Drain engine coolant. Refer to 

CO-89, "Draining"

 .

CAUTION:

Perform this step when the engine is cold.

2.

Remove battery. Refer to 

PG-155, "Removal and Installation"

.

3.

Remove air inlet tube from turbocharger. Refer to 

EM-382, "Exploded View"

.

1.

EGR volume control valve

2.

Turbocharger air inlet pipe

3.

EGR low pressure assembly bracket

4.

Gasket

5.

EGR cooler

6.

EGR cooler outlet temperature sen-
sor

7.

Diesel particulate filter

8.

Water hose

9.

EGR heat shield

10. Water hose

11.

Intake manifold

12. Gasket

13.

EGR low pressure volume control 
valve

Refer to 

GI-4, "Components"

 for symbols in the figure.

E1BIA1202GB

EM-386

< REMOVAL AND INSTALLATION >

[R9M]

EGR SYSTEM

4.

Remove air duct assembly. Refer to 

EM-380, "Exploded View"

. 

5.

Remove cowl top cover and extension cowl top. Refer to 

EXT-29, "Removal and Installation"

.

6.

Remove diesel particle filter. Refer to 

EX-24, "Removal and installation"

.

7.

Remove the swirl valve. Refer to 

EM-387, "Exploded View"

.

8.

Remove EGR volume control valve on the intake manifold.

CAUTION:

• Handle carefully to avoid any shock to EGR volume control valve.
• Never disassemble EGR volume control valve.
• Cover engine openings to avoid entry of foreign materials.

9.

Remove low pressure EGR volume control valve on the EGR cooler.

CAUTION:

• Handle carefully to avoid any shock to EGR volume control valve.
• Never disassemble EGR volume control valve.
• Cover engine openings to avoid entry of foreign materials.

10. Remove EGR heat shield.
11. Disconnect water hose on the EGR cooler.

12. Remove EGR cooler outlet temperature sensor.

13. Remove EGR cooler.
14. Remove EGR cooler tube.

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

INSTALLATION

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

CAUTION:

Clean each joint surface before installation.

1.

Perform "EGR volume control valve position learning". Refer to 

EC9-151, "Work Procedure"

. when remov-

ing or replacing EGR volume control valve.

2.

Perform "Low pressure EGR volume control valve position learning". Refer to 

EC9-152, "Work Proce-

dure"

. when removing or replacing low pressure EGR volume control.

INTAKE MANIFOLD

EM-387

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INTAKE MANIFOLD

Exploded View

INFOID:0000000010281979

Removal and Installation

INFOID:0000000010281980

REMOVAL

1.

Remove air duct (inlet). Refer to 

EM-380, "Exploded View"

.

2.

Remove air inlet hose 1 and air inlet tube 1. Refer to 

EM-382, "Exploded View"

.

3.

Use a refrigerant equipment to discharge the refrigerant.

4.

Remove low pressure flexible hose fixing bolt from compressor and high pressure flexible hose fixing bolt
from compressor. 

5.

Put aside low pressure flexible hose and high pressure flexible hose.

6.

Remove throttle valve from intake manifold.

7.

Remove swirl valve from intake manifold. 

8.

Remove EGR volume controle valve from intake mainifold.

CAUTION:

1.

Intake manifold

2.

gasket

3.

Cylinder head

4.

Throttle valve

5.

O-ring

6.

Swirl valve

7.

Air inlet pressure and temperature 
sensor

8.

Gasket

9.

EGR volume controle valve

10. Gasket

11. Gasket

A.

Refer to 

EM-387, "Removal and In-

stallation"

B.

Refer to 

EM-387, "Removal and In-

stallation"

Refer to 

GI-4, "Components"

 for symbols in the figure.

E1BIA1203GB

EM-388

< REMOVAL AND INSTALLATION >

[R9M]

INTAKE MANIFOLD

• Handle carefully to avoid any shock to EGR volume control valve.
• Never disassemble EGR volume control valve.

9.

Disconnect coolant outlet unit regulation solenoide valve con-
nector (1).

10. Unclip coolant outlet unit regulation solenoide valve connector

harness (2) and put aside.

11. Unclip water hose (3) from coolant outlet unit regulation sole-

noide valve bracket (4).

12. Disconnect vacuum hose (5) from coolant outlet unit regulation

solenoide valve. 

13. Remove coolant outlet unit regulation solenoide valve (6) and

bracket (4) assembly.

14. Remove oil level gauge and oil level gauge guide.

15. Remove water hose from intake manifold. 
16. Disconnect terminal nut and connector from the alternator.

17. Remove engine harness bracket nuts (1) and bolt (3).

18. Unclip coolant temperature sensor (3).

19. Put aside engine harness.

20. Unclip vacuum hose on the intake manifold and put aside.
21. Remove intake manifold with the following procedure:

a.

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

b.

Remove intake manifold and gasket.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

INSTALLATION

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

CAUTION:

• Clean each joint surface before installation.
• Replace intake manifold stud if loosened.

Intake Manifold

E1BIA0612ZZ

E1BIA0613ZZ

: Engine front

E1BIA0579ZZ

 : 8 N·m ( 0.8 kg-m, 71 in-lb) 

INTAKE MANIFOLD

EM-389

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1.

Install gasket to cylinder head as shown in the figure.

2.

Install intake manifold.
• Tighten mounting nuts in two steps separately.

3.

Perform "Throttle valve position learning". Refer to 

EC9-149, "Work Procedure"

. and "Swirl control valve

position learning". Refer to 

EC9-150, "Work Procedure"

. when removing or replacing throttle valve or swirl

valve.

4.

Perform "EGR volume control valve position learning". Refer to 

EC9-151, "Work Procedure"

. when remov-

ing or replacing EGR volume control valve.

5.

When replacing EGR volume control valve, throttle valve or swirl valve, this procedure must be per-
formed. Refer to 

EC9-143, "Special Repair Requirement List"

Inspection

INFOID:0000000010281981

INSPECTION AFTER REMOVAL

Surface Distortion

• Check the surface distortion of the intake manifold mating surface with a straightedge and a feeler gauge.

• If it exceeds the standard, replace intake manifold.

: Engine front

E1BIA0580ZZ

: Engine front

 First step: 10 N·m ( 1.0 kg-m, 7 ft-lb) 

E1BIA0579ZZ

 Second step: 25 N·m ( 2.6 kg-m, 18 ft-lb) 

Standard

: Refer to 

EM-472, "Intake Manifold"

.

EM-390

< REMOVAL AND INSTALLATION >

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TURBOCHARGER

TURBOCHARGER

Exploded View

INFOID:0000000010281982

Removal and Installation

INFOID:0000000010281983

REMOVAL

1.

Disconnect the battery from negative terminal.

2.

Remove air inlet tube from turbocharger. Refer to 

EM-382, "Exploded View"

.

1.

Turbocharger air inlet pipe

2.

Air inlet pipe 1

3.

Diesel particle filter bracket

4.

Turbocharger

5.

Oil tube

6.

Exaust gas pressure sensor

7.

Gasket

8.

Oil tube

9.

Exhaust gas pressure sensor tube

10. Exhaust gas temperature sensor

11.

Oil tube

12. O-ring

13. Exhaust manifold

14. Exhaust manifold gasket

15. Exhaust manifold heat shield gas-

ket

A.

Refer to 

EM-390, "Removal and Installa-

tion"

B.

Refer to 

EM-390, "Removal and In-

stallation"

C.

Refer to 

EM-393, "Removal and 

Installation"

D.

Refer to 

EM-390, "Removal and Installa-

tion"

Refer to 

GI-4, "Components"

 for symbols in the figure.

E1BIA1204GB

TURBOCHARGER

EM-391

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3.

Remove air duct assembly. Refer to 

EM-380, "Exploded View"

.

4.

Remove cowl top cover and extension cowl top. Refer to 

EXT-29, "Removal and Installation"

.

5.

Disconnect vacuum hose from turbocharger.

6.

Remove exhaust front tube. Refer to 

EX-22, "Removal and Installation"

.

7.

Remove diesel particle filter. Refer to 

EX-24, "Removal and installation"

 .

8.

Remove oil tube from turbocharger.

9.

Remove exhaust gas temperature sensor. Refer to 

EX-27, "EXHAUST GAS TEMPERATURE SENSOR

ON THE EXHAUST GAS COOLER : Removal and installation"

.

10. Remove exhaust gas pressure sensor and exhaust gas pressure tube assembly. Refer to 

EX-29,

"Removal and installation"

.

CAUTION:

Be careful not to impact or damage exhaust gas pressure sensor.

11. Remove turbocharger from exhaust manifold.

CAUTION:

Never disassemble or adjust the turbocharger body.

INSTALLATION

Note the following and install in the reverse order of removal.

CAUTION:

• Clean each joint surface before installation.
• Replace turbocharger stud if loosened.

1.

Install turbocharger.
• Tighten the mounting nuts in two steps separately.

Inspection

INFOID:0000000010281984

INSPECTION AFTER REMOVAL

Turbocharger

Check there is no leakage on the different side of the turbocharger (exhaust gas and oil) 

 : 9 N·m ( 0.9 kg-m, 80 in-lb) 

1st step: 15.0 N·m (1.5 kg-m, 11 ft-lb)

 2nd step: 25.0 N·m (2.6 kg-m, 18 ft-lb)

E1BIA0653ZZ

EM-392

< REMOVAL AND INSTALLATION >

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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 malfunction:

Turbocharger Boost Control

• Connect the handy vacuum pump (A) to the actuator, and check

that the rod strokes smoothly in compliance with the following
pressure.

INSPECTION AFTER INSTALLATION

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

Suction side:

Between turbocharger and air cleaner

Between turbocharger and charge air cleaner

Exhaust side:

Between turbocharger and diesel particle filter

Between turbocharger and exhaust manifold

Standard (value of vacuum/value of rod moving): 

Refer to 

EM-473, "Turbocharger"

.

JPBIA0665ZZ

EXHAUST MANIFOLD

EM-393

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EXHAUST MANIFOLD

Exploded View

INFOID:0000000010281985

Removal and Installation

INFOID:0000000010281986

REMOVAL

1.

Disconnect battery negative terminal.

2.

Remove diesel particle filter. Refer to 

EX-24, "Removal and installation"

.

3.

Remove turbocharger. Refer to 

EM-390, "Removal and Installation"

.

4.

Remove air cleaner case. Refer to 

EM-380, "Removal and Installation"

.

5.

Remove exhaust gas pressure sensor. Refer to 

EX-29, "Removal and installation"

6.

Remove exhaust gas temperature sensor. Refer to 

EX-27, "EXHAUST GAS TEMPERATURE SENSOR

ON THE EXHAUST GAS COOLER : Removal and installation"

7.

Remove exhaust manifold.

1.

Exhaust manifold gasket

2.

Exhaust manifold

3.

Exhaust manifold heat shield gasket 

4.

Cylinder head

A.

Refer to 

EM-393, "Removal and In-

stallation"

B.

Refer to 

EM-393, "Removal and In-

stallation"

C.

Refer to 

EM-393, "Removal and In-

stallation"

Refer to 

GI-4, "Components"

 for symbols in the figure.

E1BIA1205GB

EM-394

< REMOVAL AND INSTALLATION >

[R9M]

EXHAUST MANIFOLD

• Loosen mounting nuts in the reverse order as shown in the fig-

ure.

8.

Remove gasket.

CAUTION:

• Cover engine openings to avoid entry of foreign materials.

INSTALLATION

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

CAUTION:

• Clean each joint surface before installation.
• Replace exhaust manifold stud if loosened.

1.

Install gasket to cylinder head as shown in the figure.

2.

Install exhaust manifold.
• Tighten the mounting nuts in two steps separately in numerical

order as shown in the figure.

3.

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

Inspection

INFOID:0000000010281987

INSPECTION AFTER REMOVAL

Surface Distortion

• Check the surface distortion of the exhaust manifold mating surface with a straightedge and a feeler gauge.

: Engine front

E1BIA0581ZZ

 : 9 N·m ( 0.9 kg-m, 80 in-lb) 

: Engine front

E1BIA0583ZZ

: Engine front

1st step: 15.0 N·m (1.5 kg-m, 11 ft-lb)

 2nd step: 30.0 N·m (3.1 kg-m, 22 ft-lb)

E1BIA0581ZZ

Standard

: Refer to 

EM-472, "Exhaust Manifold"

.

EXHAUST MANIFOLD

EM-395

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• If it exceeds the standard, replace exhaust manifold.

INSPECTION AFTER INSTALLATION

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

EM-396

< REMOVAL AND INSTALLATION >

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OIL PAN (LOWER) AND OIL STRAINER

OIL PAN (LOWER) AND OIL STRAINER

Exploded View

INFOID:0000000010281988

Removal and Installation

INFOID:0000000010281989

REMOVAL

1.

Remove engine undercover.

2.

Drain engine oil. Refer to 

LU-49, "Draining"

.

CAUTION:

Perform this step when engine is cold.

3.

Remove oil pan (lower) with the following procedure:

a.

Loosen mounting bolts in reverse order shown in the figure.

1.

Cylinder block

2.

Bush

3.

TDC pin plug 

4.

Gasket

5.

Oil pan drain plug

6.

Oil pan (lower) bolt

7.

Oil pan (lower)

8.

Oil pan (upper)

9.

Oil pan (upper) bolt

A.

Refer to 

EM-396, "Removal and In-

stallation"

B.

Refer to 

EM-437, "Removal and In-

stallation"

Refer to 

GI-4, "Components"

 for symbols in the figure.

E1BIA1206GB

E1BIA0582ZZ

OIL PAN (LOWER) AND OIL STRAINER

EM-397

< REMOVAL AND INSTALLATION >

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b.

Insert the seal cutter [SST:KV10111100 ( — )] (A) between oil
pan (upper) and oil pan (lower). Slide tool by tapping on the side
of the tool with a hammer.

CAUTION:

• Be careful not to damage mating surface.
• Never insert screwdriver, or oil pan flange will be

deformed.

c.

Remove oil pan (lower).

4.

Remove oil strainer.
• Loosen mounting bolt.

INSTALLATION

1.

Install oil strainer.
• Tighten oil strainer mounting bolts.

2.

Install oil pan (lower) with the following procedure:

a.

Use a scraper (A) to remove old liquid gasket from mating sur-
faces.

CAUTION:

Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
• Remove old liquid gasket from the bolt holes and threads.

JPBIA0276ZZ

E1BIA0647ZZ

: 10.0 N·m (1.0 kg-m, 7 ft-lb)

E1BIA0647ZZ

JPBIA0025ZZ

EM-398

< REMOVAL AND INSTALLATION >

[R9M]

OIL PAN (LOWER) AND OIL STRAINER

b.

Apply a continuous bead of liquid gasket with the 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 coating.

c.

Tighten mounting bolts in two steps separately in numerical
order as shown in the figure.

3.

Install in the reverse order of removal, for the rest of parts.
NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.

Inspection

INFOID:0000000010281990

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-48, "Inspection"

.

2.

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

3.

Stop engine and wait for 10 minutes.

4.

Check the engine oil level again. Refer to 

LU-48, "Inspection"

.

a

: 3.0 - 7.0 mm (0.118 - 0.276 in)

: Engine front

JPBIA0648ZZ

1st step: 5.0 N·m (0.51 kg-m, 44 in-lb)

2nd step: 12.0 N·m (1.2 kg-m, 9 ft-lb)

E1BIA0582ZZ

GLOW PLUG

EM-399

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GLOW PLUG

Exploded View

INFOID:0000000010281991

Removal and Installation

INFOID:0000000010281992

REMOVAL

CAUTION:

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

1.

Disconnect the battery cable from the negative terminal.

2.

Remove air inlet hose 1. Refer to 

EM-382, "Exploded View"

3.

Remove damper valve from intake manifold. Refer to 

EM-387, "Exploded View"

4.

Remove swirl valve from intake manifold. Refer to 

EM-387, "Exploded View"

5.

Disconnect harness connector from glow plug.

6.

Remove glow plug.

CAUTION:

• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal.

INSTALLATION

1.

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

2.

Install glow plug.

3.

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

1.

Glow plug

Refer to 

GI-4, "Components"

 for symbols in the figure.

E1BIA1207GB

EM-400

< REMOVAL AND INSTALLATION >

[R9M]

VACUUM PUMP

VACUUM PUMP

Exploded View

INFOID:0000000010281993

Removal and Installation

INFOID:0000000010281994

REMOVAL

1.

Remove battery. Refer to 

PG-155, "Removal and Installation"

.

2.

Disconnect vacuum hoses.

3.

Remove vacuum pump.
• Loosen mounting bolts in reverse order as shown in the figure.

INSTALLATION

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

Vacuum pump

1.

Vacuum pump

2.

Gasket

3.

Vacuum hose

A.

To brake booster

B.

To turbocharger boost control sole-
noid valve

C.

To coolant outlet unit regulation sole-
noid valve

Refer to 

GI-4, "Components"

 for symbols in the figure.

E1BIA1208GB

E1BIA0614ZZ