Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD)

ENGINE ASSEMBLY

EM-433

< UNIT REMOVAL AND INSTALLATION >

[R9M]

Remove stabilizer connecting rod mounting nut and cap at strut side (RH and LH). Refer to

FSU-18,

"Removal and Installation"

Disconnect intermediate shaft to steering column assembly. Refer to

ST-10, "Exploded View"

Disconnect clutch pipe. Refer to

CL-15, "Exploded View"

10. Remove front suspension member. Refer to

FSU-21, "Removal and Installation"

11. Preparation for the separation work of transaxle is as follows:

• Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side.

Removal

Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a transmission jack. Securely support
bottom of the engine and the transaxle assembly.

CAUTION:

Put a piece of wood or an equivalent as the supporting sur-
face, secure a completely stable condition.

Remove upper torque rod.

Remove mounting bolts on engine mounting insulator (RH).

Remove mounting bolts on engine mounting insulator (LH).

Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work,
observe the following caution.

CAUTION:

• Check that no part interferes with the vehicle side.
• Before and during this lifting, always check if any harnesses are left connected.
• During the removal, always be careful to prevent the vehicle from falling off the lift due to

changes in the center of gravity.

• If necessary, support the vehicle by setting jack or suitable tool at the rear.

Separation

Set a hoist to engine slinger (rear side) (1) and engine slinger
(front side) (2).

Remove starter motor. Refer to

STR-32, "R9M : Removal and Installation"

Lift with a hoist and separate the engine from the transaxle assembly. Refer to

EM-440, "Exploded View"

INSTALLATION

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

CAUTION:

• Never allow engine oil to get on engine mounting insulator. Be careful not to damage engine mount-

ing insulator.

• Check that each mounting insulator is seated properly, and tighten mounting nuts and bolts.

PBIC1190E

: Engine front

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EM-434

< UNIT REMOVAL AND INSTALLATION >

[R9M]

ENGINE ASSEMBLY

Inspection

INFOID:0000000010282015

INSPECTION AFTER INSTALLATION

Inspection for Leaks

• 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 make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-

ing 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

Transmission / transaxle
fluid

MT Models

Level / Leakage

Leakage

Level / Leakage

Other oils and fluid*

Level

Leakage

Level

Fuel

Leakage

Exhaust gases

—

Leakage

—

ENGINE STAND SETTING

EM-435

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

UNIT DISASSEMBLY AND ASSEMBLY

ENGINE STAND SETTING

Setting

INFOID:0000000010282016

NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc.
1.

Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to

EM-429, "Exploded View"

Install engine to engine stand with the following procedure:

Remove flywheel. Refer to

EM-447, "Disassembly and Assembly"

• Secure crankshaft using a crankshaft pulley locking tool [SST: — (Mot.1770)], and remove mounting

bolts.

CAUTION:

Never disassemble them.

Lift the engine with a hoist to install it onto widely use engine stand.

CAUTION:

Use the engine stand that has a load capacity [approximately 225 kg (496 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-

tial risk of overturning stand.

- Intake manifold: Refer to

EM-387, "Exploded View"

- Exhaust manifold: Refer to

EM-393, "Exploded View"

- Oil separator: Refer to

EM-402, "Exploded View"

NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel
removed.

CAUTION:

Before removing the hanging chains, check the engine
stand is stable and there is no risk of overturning.

Drain engine oil. Refer to

LU-49, "Draining"

CAUTION:

Be sure to clean drain plug and install with new gasket.

PBIC3227J

EM-436

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

ENGINE UNIT

ENGINE UNIT

Disassembly

INFOID:0000000010282017

Preparing the old engine to be returned to the engine renovation plant

Clean the engine

Drain the oil and coolant from the used engine.

Secure the old engine to the stand and in the same conditions as the standard replacement engine :
• fit the plastic plug welds and covers,
• fit the cardboard cover over the whole assembly.

Parts to leave on the old engine or to include in the return box:
• the dipstick,
• the oil filter,
• the oil filter unit,
• the cylinder head,
• the water pump,
• the vaccum pump,
• the high pressure pump,
• the injectors,
• the heater plugs,
• the crankshaft accesories pulley,
• the cylinder head suspended mounting.

Parts to be removed from the old engine and fitted on the new engine
• all the coolant circuit pipes,
• the coolant pump inlet pipe,
• the coolant inlet unit,
• the intake manifold,
• the exhaust manifold,
• the turbocharger,
• the exhaust gas recirculation solenoid valve,
• the damper valve,
• the exhaust gas recirculation low pressure solenoid valve,
• the exhaust gas cooler,
• the swirl valve,
• the particle filter,
• the alternator,
• the air conditioning compressor,
• the clutch mechanism-plate,
• the flywheel.

Assembly

INFOID:0000000010282018

Assembly is the reverse order of disassembly.

OIL PAN (UPPER)

EM-437

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

OIL PAN (UPPER)

Exploded View

INFOID:0000000010282019

Removal and Installation

INFOID:0000000010282020

REMOVAL

Remove oil pan (lower). Refer to

EM-396, "Removal and Installation"

Remove oil strainer and oil pump. Refer to

LU-55, "Exploded View"

Remove rear oil seal retainer. Refer to

EM-427, "REAR OIL SEAL : Removal and Installation"

Remove oil pan (upper) with the following procedure:

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

Cylinder block

Bush

TDC pin plug

Gasket

Oil pan drain plug

Oil pan (lower) bolt

Oil pan (lower)

Oil pan (upper)

Oil pan (upper) bol

10. Bush

Refer to

EM-396

Refer to

EM-437, "Removal and In-

stallation"

Refer to

GI-4, "Components"

for symbols in the figure.

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EM-438

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

OIL PAN (UPPER)

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

CAUTION:

• Be careful not to damage mating surface.

Remove the oil pan (upper) from the cylinder block.

INSTALLATION

Install oil pump and oil pump baffle plate with the following procedure:

Install oil pump (1), oil pump baffle plate, oil pump drive chain
and oil pump sprocket.

Tighten oil pump mounting bolts (A) in two steps.

Tighten oil stainer bolt (B).

Install oil pan (upper) with the following procedure:

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.
• Also remove old liquid gasket from mating surface of cylinder

block.

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

Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to areas shown in the figure.

Use Genuine Liquid Gasket or equivalent

CAUTION:

• At the bolt holes marked, liquid gasket should be applied

inside holes.

• Attaching should be done within 5 minutes after coating.

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

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

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

: 8.0 N·m (1 kg-m, 7 ft-lb)

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: 3.0 - 7.0 mm (0.118 - 0.276 in)

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1st step: 10.0 N·m (1.0 kg-m, 7 ft-lb)

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

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OIL PAN (UPPER)

EM-439

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

Install rear oil seal retainer. Refer to

EM-427, "REAR OIL SEAL : Removal and Installation"

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.

EM-440

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

CYLINDER HEAD

CYLINDER HEAD

Exploded View

INFOID:0000000010282021

Disassembly and Assembly

INFOID:0000000010282022

DISASSEMBLY

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

EM-390, "Exploded View"

• Intake manifold: Refer to

EM-387, "Exploded View"

• Exhaust manifold: Refer to

EM-393, "Exploded View"

• Water outlet and thermostat assembly: Refer to

EM-446, "Exploded View"

• Front cover, timing chain: Refer to

EM-446, "Exploded View"

• Camshaft: Refer to

EM-440, "Exploded View"

E1BIA0660GB

Cylinder head

Cylinder head gasket

Engine slinger

Cylinder head bolt

Valve

Valve oil seal

Valve spring

Valve spring retainer

Valve collet

10.

Tappet

11.

Hydraulic tappet

12 Valve rocker clips

13.

Slinger bolt

14. Bush

Refer to

EM-447, "Disassembly and Assembly"

Refer to

GI-4, "Components"

for symbols in the figure.

CYLINDER HEAD

EM-441

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

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

Remove cylinder head gasket.

Set the cylinder head assembly to the cylinder head support [commercial service tool: KV113B0200
(Mot.1573)].

Remove hydraulic tappet.

CAUTION:

Be sure to immerse the hydraulic tappets in a bath of engine oil to ensure no air enters.

Remove valve collet (1).
• Compress valve spring with valve spring compressor (com-

mercial service too) (A).

Remove valve spring retainer and valve spring.

Check dimension of valve oil seal mounting position before removing valve and valve oil seal with the fol-
lowing procedure:

Install the push rod (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot.1511-01)] on the valve oil seal.
NOTE:
The inner diameter of the push rod must be identical to that of
the valve. In addition, the bottom of the push rod must come into
contact with the metal upper section of the valve oil seal.

Install the guide tube (B) over the push rod (A) until the guide
tube comes into contact with the cylinder head, locking the push
rod with the knurled wheel.
• Remove the guide tube assembly plus push rod, being careful

not to loosen the knurled wheel.

Push valve stem to combustion chamber side, and remove valve.

: Engine front

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EM-442

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

CYLINDER HEAD

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

10. Remove valve oil seal (1) with a valve oil seal puller [commercial

service tool: KV113B0090 (Mot.1335)] (A).

ASSEMBLY

Install valve.
NOTE:
Install larger diameter to intake side.

Install valve oil seal with the following procedure:

Position the protector (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot.1511-01)] on the valve.

Position a valve oil seal on the protector. Move the valve oil seal past the protector.

CAUTION:

Never lubricate valve oil seal.

Remove the protector.

Push in the push rod (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot. 1511-01)] with palm of the hand until the
guide tube (B) makes contact with the cylinder head.

Install valve spring.
NOTE:
The intake and exhaust valve springs are identical.

Install valve spring retainer.

Install valve collet (1).

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CYLINDER HEAD

EM-443

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

• Compress valve spring with a valve spring compressor (com-

mercial service tool) (A).

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

lation to check its installed condition.

Install hydraulic tappet.
• Check that the tappets are filled with oil before refitting them.

Install cylinder head gasket with the following procedure:

CAUTION:

Before installing cylinder head, inspect piston protrusion.

Apply liquid gasket to position (A) shown in the figure.

Use Genuine Liquid Gasket or equivalent.

Install cylinder head gasket (1), and apply liquid gasket to posi-
tion (A) shown in the figure.

Use Genuine Liquid Gasket or equivalent.

Install cylinder head, and tighten mounting bolts in numerical
order as shown in figure with the following procedure:

Tighten all bolts.

JPBIA0643ZZ

: Engine front

JPBIA0612ZZ

: Engine front

JPBIA0611ZZ

: Engine front

: 5.0 N·m (0.51 kg-m, 44 in-lb)

: 30.0 N·m (3.1 kg-m, 22 ft-lb)

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EM-444

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

CYLINDER HEAD

Turn all bolts 300 degrees clockwise (angle tightening).

CAUTION:

Check and confirm the tightening angle by using an angle
wrench [SST: KV10112100 ( — )] (A) or protractor. Never
judge by visual inspection without the tool.

Assemble in the reverse order of disassembly, for the rest of parts.

Inspection

INFOID:0000000010282023

INSPECTION AFTER DISASSEMBLY

Cylinder Head Distortion

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

At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions (A - F).

• If it exceeds the standard, replace cylinder head and cylinder

head housing.

NOTE:
Cylinder head cannot be replaced as a single part, because it is
machined together with cylinder head housing. Replace whole
cylinder head housing and cylinder head assembly.

VALVE DIMENSIONS

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

EM-473, "Cylinder Head"

• If dimensions are out of the standard, replace valve and check valve seat contact.

VALVE GUIDE CLEARANCE

Valve Stem Diameter

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

Valve Guide Inner Diameter

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

Valve Guide Clearance

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

stem diameter)

• If it exceeds the standard, replace valve and/or cylinder head and cylinder head housing.

VALVE SEAT CONTACT

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Standard: Refer to

EM-473, "Cylinder Head"

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Standard

: Refer to

EM-473, "Cylinder Head"

Standard

: Refer to

EM-473, "Cylinder Head"

Standard :

Refer

EM-473, "Cylinder Head"

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CYLINDER HEAD

EM-445

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

• 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 re-check, replace
cylinder head and cylinder head housing.

VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

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

specified spring height.

• If the pressure height is out of the standard, replace valve spring.

: OK

: NG

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Standard

: Refer to

EM-473, "Cylinder Head"

SEM113

EM-446

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

CYLINDER BLOCK

CYLINDER BLOCK

Exploded View

INFOID:0000000010282024

Centring dowe

Cylinder block

TDC hole plug

Scraper ring

Sealing ring

Compression ring

Gudgeon pin locking spring ring

Piston

Con rod

E1BIA1216GB

CYLINDER BLOCK

EM-447

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

Refer to

GI-4, "Components"

for symbols shown in the figure.

Disassembly and Assembly

INFOID:0000000010282025

Disassembly

Remove oil level sensor.

CAUTION:

Handle it carefully and avoid impacts.

Remove crankshaft position sensor.

CAUTION:

• Handle it carefully and avoid impacts.
• Never place sensor in a location where it is exposed to magnetism.

Remove rear oil seal retainer.

Remove pilot bushing using the pilot bushing puller (commercial service tool), if necessary.

Remove oil pan (upper). Refer to

EM-437, "Exploded View"

Remove oil pump related parts. Refer to

EM-412, "Exploded View"

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-459, "Inspection"

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

Remove connecting rod cap.
• Put a paint mark on cap to identify each cylinder.

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 oil jets (A), cylinder wall and

crankshaft pin, resulting from an interference of the con-
necting rod big end.

• Never disassemble oil jets.

10. Piston pin

11.

Con rod bearing shell

12.

Con rod bolt

13. crankshaft thrust washer

14.

Flywheel bolts (M/T Models)

15.

Flywheel (M/T Models)

16. Crankshaft seal on gearbox end bolt

17.

Crankshaft seal on gearbox end

18.

Crankshaft bearing shell

19. Crankshaft bearing cap

20.

Crankshaft bearing cap bolt

21.

Crankshaft

22. Timing sprocket

23.

Oil pan upper

24.

Oil pan upper bolts

25. Drive plate (CVT Models)

26.

Pilot bushing

Refer to

Refer to

Refer to

PBIC0259E

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EM-448

< UNIT DISASSEMBLY AND ASSEMBLY >

[R9M]

CYLINDER BLOCK

Remove connecting rod bearings.

CAUTION:

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

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

EM-459, "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.

10. Remove the snap rings (1) using a screwdriver (A), and then

release the piston pin.

11. Remove main bearing cap mounting bolts with the following procedure:

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

EM-459,

"Inspection"

NOTE:
Always mark the position of each crankshaft bearing shell using
an indelible marker pen, in relation to the crankshaft bearing
number

Remove:

• the crankshaft bearing cap bolts,
• the crankshaft bearing caps,
• the crankshaft,
• the cranshaft bearing shells.

NOTE:
Always mark the position of each crankshaft bearing shell using an
indelible marker pen, in relation to the crankshaft bearing number
12. Remove the crankshaft thrust washer (1)

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: Channel

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Qashqai J11. Engine mechanical (HRA2DDT, K9K, MR20DD) - part 28