Product Campaign Bulletin - Nissan Extranet Technical... · Product Campaign Bulletin Nissan Ireland Cedar House Park West Business Park Nangor Road, Dublin 12 . Ken Ward . ... F15

Ken Ward

REFERENCE: PCB-NES-16-001

MODEL: F15 Juke

SUBJECT: PCB FG15 - PG6B0 - ECM Reprogram - 1.5 K9K Diesel Engine

_____________________________________________________________________________

Product Campaign

Bulletin

Nissan Ireland

Cedar House

Park West Business Park

Nangor Road, Dublin 12

Ken Ward

Ken Ward

Ken Ward

REPAIR PROCESS

REPAIR PROCESS - ECM 1.5 Litre Diesel Engine

Dealer confirms if vehicle is affected

by campaign PG6B0?

Dealer checks VIN in eNEWS

Dealer performs repair procedure PG6B00

No further action required

Dealer submits claim

YES

NO

Is vehicle mileage ≥3,000km?

Dealer performs repair procedure PG6B01

Dealer submits claim

NO

Dealer reprograms ECM Dealer reprograms ECM

Dealer replaces DPF

Dealer sets LNT value Dealer sets LNT value

Ken Ward

Precautions

<Condition of the vehicle>

• Erase all recorded DTC in the vehicle before reprogramming.

• Turn off all the electric loads.

• Do NOT use mobile phone or devices that emit electromagnetic waves, such as radio transceivers etc., near the

vehicle.

• Connect battery charger/stabilizer to the 12V battery and control the output to maintain the voltage always within

12V to 13.5V.

• Ensure all doors are closed and the driver's window is in the fully down position.

• During the reprogramming do not switch OFF the ignition.

• If the engine has been running, ensure the ignition is OFF for at least 30 seconds to allow time for the ECM to reset

before conducting the rework.

<Condition of Consult IIIplus>

• Be sure to have the AC Adapter to your Consult IIIplus connected, during the reprogramming.

• Switch off screen saver of your Consult IIIplus

• Connect VI with USB cable, and do not disconnect during the reprogramming.

• If further reprogram is to be conducted for another vehicle after completion of the reprogram, turn off Consult

IIIplus completely before continuing.

• Make sure to use Ver.53.41 or later version of Consult IIIplus software.

• Make sure the relevant Consult IIIplus patch for this activity is installed.

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REPAIR PROCEDURE

Connect 12V battery charger/stabilizer to the vehicle battery.

NOTE: Make sure all the key points in the precautions section are followed.

Connect the VI Unit to the vehicle port and to Consult IIIplus using USB connection.

Change the vehicle condition to "ON", by operating the ignition switch.

Start up Consult IIIplus and confirm that the VI is connected to the vehicle and to Consult IIIplus by USB connection.

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Click on "Diagnosis (All Systems)" and select the appropriate vehicle to be reprogrammed.

Check that there are no DTCs recorded or solve/erase all recorded DTCs before continuing.

NOTE: The DTCs below may be shown reprogramming can be completed without erasing them.

Click on "Home" button and then "Diagnosis (One System)"

Click on "Engine" button and check there are no DTCs recorded.

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Select "ECU Identification" tab.

NOTE: find below table with affected ECU IDs, if the vehicle is within the affected VIN list but the ECU Identification is

not included in this table, contact Technical Support Department.

In "Work Support" tab select "Saving Data for Replc CPU" and complete the process clicking "Start" and then "End" once

completed.

Click on "Home" button and then "Re/programming, Configuration"

Vehicle NG Software dataset

F15 K9K Gen6 Euro6b+

23710 HY02B

23710-HY02B

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Read and follow the precautions and tick the confirmation check box, then click on "Next".

NOTE: Any precautions added in Consult IIIplus after the release of this bulletin must also be followed.

Select the appropriate vehicle to be reprogrammed, click on "Select" and then click "Confirm".

Enter the VIN number and click on "Confirm".

NOTE: VIN should be automatically identified, insert it manually otherwise.

Click on "Engine" button. Then click on the "Reprogramming" button.

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NOTE: table below shows compatibility at the release of the campaign, any later ECM Part Number update (unrelated

to the campaign) will not be included in this table.

Confirm output of the charger/stabilizer result is OK and click on "Next".

Check that the part number shown is included in the table in step 9 and touch the “Save” button. Then click on "Next" button.

Read both precaution pages, tick the confirmation check box and click on "Next".

NOTE: Any precautions added in Consult IIIplus after the release of this bulletin must also be followed.

Confirm that the Part number after reprogramming is according to the table below and click "Next".

F15 K9K Gen6 Euro6b+ 23710 HY02B 23710 HY02E

Vehicle NG Software dataset Countermeasure software dataset

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Confirm voltage of the 12V battery is OK, the reprogramming conditions are met and click on "Start".

Wait until "Transfer VI to ECU" is 100% and then click "Next".

NOTE: follow all the indications in the precautions sections, failing to do so may result in damage to the vehicle. Refer

to the "Troubleshooting" section at the end of this document.

Operate the ignition switch to OFF status and wait for the system to update the status to OFF. Then operate the ignition switch

to ON.

Confirm the performed reprogramming.

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Check that the keys work correctly, start the engine and that there is no warning light.

NOTE: It may be necessary to start the engine to erase some of the DTCs.

Some DTCs may be shown.

Click "Home" button and click on "Diagnosis (All Systems)".

Click on "Engine" button.

END OF REPAIR PROCEDURE

Select "Work support" tab and click on "WRITING DATA FOR REPLC CPU". Then click on "Start" button.

Wait until "CMND FINISHED" is shown on the screen, then click "End". Erase all DTCs and check that no DTC are present. Quit

Consult IIIplus and disconnect VI. Then disconnect the 12V battery charger/stabilizer.

Ken Ward

TROUBLESHOOTING

More than one Part Number option is shown for reprogramming

Use Part Number after reprogramming and Other information to select the correct option for the affected vehicle. Tables are

given within the repair procedure to ensure PN information is available.

No option is shown for reprogramming or the reprogramming button is not active

Make sure the reprogramming patch has been correctly installed following the instructions at the end of the procedure. Make

sure the Part Number of the unit is affected by the activity.

An error message is shown when transfering data to the control unit

Make sure all items in the precaution section are followed. Failing to do so may result in permanent damage to the control unit.

Contact your NSC Technical Assistance Department.

NOTE: if the control unit is no longer detected by Consult IIIplus permanent damage may have been caused to the

control unit and replacement may be necessary.

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HOW TO CHECK Consult IIIplus VERSION

The software version can be checked on the top left corner of the screen of Consult IIIplus.

HOW TO DOWNLOAD & INSTALL THE REPROGRAMMING PATCH

Log into N-FIT on the B2B portal, then select the Programming data search option in the left window pane .

Select F15 vehicle as appropriate and click on "Search"

Select Engine_F15_Engine and download the files within.

Reprogramming_F15_Engine_ECM_K9K Euro6b+.zip

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Save and execute the files with Consult IIIplus closed.

Select the preferred language then click OK, Next and Install.

Click on finish when installed.

COMMON ACRONYMS USED IN THE REPROGRAMMING PATCH

Acronym Explanation Acronym Explanation

EU /EUR Europe BLNK Blank

RUS Russia REPR Reprogramming

UKR Ukraine wDPF With DieselParticulateFilter

MOR Morocco w/oDPF Without DieselParticulateFilter

GOM General Overseas Market STD Standard version

SAF South Africa ECO Eco version

JPN Japan AT Automatic transmission

NAM North America M/T (MT) Manual transmission

KOR Koreea SL Speed limiter

ASR (AUS) Australia XXXkw Engine power XXXKW

XXMY ( MYXX ) Model year 20XX 2WD 2 wheels drive

E5 EURO 5 emission standard 4WD 4 wheels drive

LCV 4 /5 Light commercial vehicle ASCD With cruise control and with speed limiter

LT Light Truck tire ( e.g. D40 YD25 model) oASCD

Optional ASCD ( can be present or not , or installed

after)

ISS Intelligent Start Stop H/Usw Heat up switch

3row/2row 7 seats /5 seats T/C Turbocharger

Inj.PumpDFP3.4/Inj.

PumpDFP1.15 High pressure fuel pump type (3.4, 1.15)

Single mass/double

mass F/W Single mass/double mass flywheel

wVDC With VDC (ESP) / VDCS ICC Intelligent cruise control

w/oVDC Without VDC (ESP) / VDCS

Ken Ward

REPAIR PROCEDURE - F15 JUKE - DPF REPLACEMENT

1. Position vehicle on workshop lift.

2. Open hood.

3. Rotate the steering wheel to position the road wheels straight ahead. Use suitable tape to secure the wheel in this position for the

duration of the repair.

4. Disconnect battery at the negative and positive terminals.

5. Remove protective caps from the airconditioning system pipework and connect to approved recovery/recycling equipment to capture

the refrigerant during the discharge process.

6. After the refrigerant has been discharged from the pipework, loosen the bolt fixings of the low pressure flexible pipe of the

airconditioning system and remove the pipe. Fit blanking plugs to open the airconditioning pipe connections. If blanking plugs are not

available, use a suitable alternative.

7. Locate the turbocharger to the rear of the engine within the engine bay. Disconnect the NOx trap upstream A/F sensor harness

connector (highlighted yellow circle) and release the harness from the metal clip. Unclip the fuel pipe plastic retainer located near the

battery.

8. Remove the 3 fixings (highlighted yellow circles) of the turbocharger upper heatshield and remove the heatshield.

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9. Remove the bolt fixings (highlighted with yellow circles) of the adjacent metal support bracket.

10. Move aside the metal support bracket.

11. Loosen the V-clamp connection between the turbocharger outlet and the DPF inlet pipe and remove the nut fixing (highlighted yellow

circle).

12. Open driver's door.

13. Remove the plastic trim clips from the carpet trim cover plate on the floor at the lower end of the steering intermediate shaft .

14. Remove the bolt and the plastic guide from the intermediate steering joint and separate from the shaft of the steering gear.

trim cover

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15. Raise vehicle on lift.

Steps 16-25 should be repeated for both sides of the vehicle:

16. Remove the front road wheel.

17. Remove the cotter pin and discard it.

18. Remove the adjusting cap.

19. Loosen the wheel hub lock nut [Use hub lock nut wrench SST KV40104000 or a suitable equivalent].

20. Disengage the wheel hub assembly from the driveshaft. Use suitable protection on the wheel hub lock nut to prevent secondary

damage during the driveshaft removal.

[Use suitable puller where wheel hub and driveshaft cannot be seperated even after performing the above method]

21. Remove the wheel hub nut (see highlighted red circle) and discard it.

22. Disconnect the upper end of the stabilizer connecting rod from the strut assembly (see highlighted red circle).

23. Separate the steering arm ball joint from the steering knuckle and discard nut.

24. Loosen the lower ball joint retaining bolt and the nut fixing and separate the lower ball joint from the steering knuckle. Discard nut.

25. Separate the outboard end of the driveshaft from the steering knuckle/wheel hub assembly.

26. Repeat steps 16 to 25 for the remaining front road wheel.

upperstabiliser rod nut

lower ball joint

Ken Ward

27. Remove the bolt of the rear torque rod bracket connection to the torque rod.

28. Remove the mounting bolt of the torque rod and remove the torque rod.

29. Remove the rubber supports from the front of the exhaust system.

30. Ensure that the bracket mounting for the wiring harness of the exhaust throttle valve is disconnected from the steering gear

assembly.

31. Loosen the fixing bolts of member stay.

CAUTION: Do NOT remove the rear mounting bolts of the front suspension member at this stage.

32. Support rear of front suspension member centrally with hydraulic transmission jack (or similar).

33. Remove all member stay mounting bolts as well as the 2 rear mounting bolts of the front suspension member.

34. Carefully slide out member stay without lowering the hydraulic transmission jack. Use a paint mark to note location and orientaion of

rubber rebound stoppers sandwiched between member stay and front suspension member.

WARNING: 2 people are required to remove the front suspension member so that it can be safely lowered from the vehicle.

35. Remove the front mounting bolts (highlighted red circle) of the front suspension member whilst providing adequate support at each

front corner of the front suspension member.

36. With the 4 front suspension member mounting bolts removed, carefully lower the hydraulic transmission jack located at the rear of the

front suspension member whilst manually supporting the front end of the front suspension member throughout the removal process.

rear torque rod

member stay

exhaust rubber

mountsbracket rear mount of front

suspension member

front mount of front suspension member

Ken Ward

37. Once lowered to an appropriate height, manually lift the front suspension member off the hydraulic transmission jack and place the

complete front suspension member assembly aside.

38. Loosen the gearbox sump plug and partially drain the gearbox oil to a level just below the gearbox output shaft seal. [Ensure gearbox

oils is drained into a clean container so that the oil can be reused in the gearbox]. Ensure the sump plug washer is replaced with a new

part and torque tighten the sump bolt to 22Nm.

39. On the right side of the vehicle, loosen the bearing support cover plate bolts of the right hand driveshaft assembly and discard the

cover plate (see highlighted red circle).

40. Carefully remove the driveshaft from the gearbox differential and place aside.

41. Remove the rear torque rod bracket and driveshaft bearing support bracket.

42. Loosen the nut fixings of the exhaust flange connection to the DPF outlet (see yellow highlighted circle). Separate the flexible exhaust

end section and discard the exhaust gasket.

43.Remove the DPF outlet pipe fixing bolt (highlighted blue circle).

44. Loosen the bracket mountings and remove the bracket. Disconnect the wiring harness connections to the DPF A/F ratio sensor and

exhaust gas temperature sensor. Make note of all harness routing.

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45. Remove the nut fixings of the EGR cooler tube connection to the DPF (highlighted blue circle). Separate the EGR cooler tube from the

DPF and discard the gasket.

46. Loosen the bolt fixings of both DPF support straps

CAUTION: Do not remove support straps at this stage as DPF assembly will no longer be correctly supported.

47. Lower vehicle on lift.

48. Working from the engine bay, remove the V-clamp connector (highlighted blue circle) and separate the DPF inlet pipe from the

turbocharger outlet pipe.

49. Raise vehicle on lift.

50. Carefully move the engine forward in the engine bay and temporarily secure the engine in a forward position to allow for improved

access to the DPF assembly. [Ensure that no contact occurs between the engine components (e.g. between the intercooler and the

airconditioning pipework) to the front of the engine].

WARNING: Ensure that the engine is secure in this position and any device cannot be dislodged during the DPF removal

operation. Additional use of the hydraulic transmission jack may be necessary to provide additional support.

51. Carefully remove the DPF upstream exhaust gas temperature sensor wiring harness and the NOx trap upstream exhaust gas

temperature sensor wiring harness from the metal clips located on the DPF heat insulator located on the top of the DPF assembly. Use

paint marks to note the correct wiring harness routing.

52. Using long nose pliers (or similar tool), separate the DPF differential pressure sensor hose connections from below (see red highlighted

circle in "DPF assembly" image). Use a paint mark to note the colour and orientation of the hoses.

CAUTION: The removal of the bolt fixings of the lower straps will leave the DPF assembly supported by only its upper straps.

Due to the weight of the DPF assembly and the requirement to complete the dismantling operation from below when the

assembly is partially lowered, use a transmission jack (or similar) to support the DPF during its removal.

Ken Ward

DPF assembly

53. Remove the bolt fixings of both DPF support straps and remove the lower straps (i.e. strap section with captive nut). Discard the

lower straps

54. Remove 3 x Torx screw fixings securing the DPF heat insulator (see highlighted blue circle above).

55. Remove the upper strap fixing of the DPF assembly [routed underneath heatshield] and lower the DPF assembly. Discard the upper

straps.

56. With the DPF partially lowered, loosen and remove the DPF upstream exhaust gas temperature sensor from the DPF assembly.

57. Remove the DPF assembly from the engine bay and place aside.

DPF upper straps DPF upstream exhaust gas temp sensor

Ken Ward

58. With the DPF assembly removed, the DPF support bracket fixing bolts can be accessed. Remove the DPF support bracket and discard

it.

59. Place the DPF assembly on a work bench to complete dissassembly by removal of all sensors.

60. Identify the DPF downstream A/F ratio sensor and remove it with use of exhaust sensor removal tool [use SST MOT 1495 or a suitable

equivalent].

61. Identify the NOx trap upstream A/F sensor and remove it by using an exhaust sensor removal tool [use SST MOT 1495 or a suitable

equivalent].

62. Identify the NOx trap upstream exhaust gas temperature sensor and remove it. Use a paint mark to note the orientaion of the NOx

exhaust gas temperature sensor relative to the body of the DPF assembly.

63. Ensure that the DPF assembly is retained as it is required to be returned to Nissan Europe with the warranty parts return.

DPF bracket

DPF downstream A/Fratio sensor

NOx trap upstream A/Fratio sensor NOx trap upstream exhaust gas temp sensor

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Re-assembly [Note: 2 people are required to re-fit the front suspension member]

64. Fit the NOx trap upstream A/F sensor to the new DPF assembly and torque tighten to 44Nm.

65. Fit the NOx trap upstream exhaust gas temperature sensor and torque tighten to 30Nm. Use the paint mark to ensure correct

orientation of the sensor body.

66. Fit the DPF upstream A/F sensor and torque tighten to 44Nm.

67. Fit a new DPF mounting bracket and refit the mounting bolts. Torque tighten bolts to 25Nm.

68. Temporarily raise the DPF assembly (on hydraulic transmission jack or similar) and fit the DPF upstream exhaust gas temperature

sensor and torque tighten to 32Nm.

69. Correctly locate the upper fixing straps under the DPF insulator (and metal tube structure protruding from DPF) and secure the DPF

insulator with 3 x Torx bolt fixings.

70. Torque tighten the DPF insulator Torx bolt fixings to 10Nm.

71. Whilst supporting the DPF assembly, fit the DPF strap assembly (new lower and upper strap sections) to mounting bracket and hand

tighten fixing bolts to correctly support DPF assembly. Remove the hydraulic transmission jack.

72. Resecure the wiring harnesses into the harness clips. Ensure the correct wiring harness routing is achieved.

73. Fit a new EGR gasket and refit the flange mounting nuts. Torque tighten to 25 Nm.

74. Reconnect the DPF differential pressure sensor tubes from below using long nose pliers. Use the paint mark to ensure the correct hose

orientation and connection is achieved.

75. Lower vehicle on lift.

76. Install a new V-clamp/gasket to the DPF inlet pipe and locate the pipe correctly in the turbocharger outlet pipe.

77. Ensure the DPF assembly is correctly seated within its mounting cradle.

78. Ensure the V-clamp/gasket is correctly located over the pipe joint and torque tighten clamp fixing to 25Nm.

79. Raise vehicle on lift.

80. Torque tighten fixing bolts of the DPF support straps to 25Nm.

81. Refit the exhaust bracket and reconnect the DPF outlet to the exhaust flange. Fit a new exhaust gasket.

82. Torque tighten the exhaust flange mounting nuts to 21Nm.

83. Refit the harness support bracket of the exhaust throttle valve to the steering gear assembly.

84. Reconnect the DPF A/F ratio sensor and the exhaust gas temperature sensor harness connectors.

85. Carefully remove the gearbox differential oil seal and discard it. Install a new oil seal into the gearbox differential casing.

86. Refit the driveshaft bearing support bracket and torque tighten mounting bolts to 44Nm.

87. Clean the mating surface of the driveshaft(s) and steering knuckle/wheel hub assemblies and then apply 1 to 3 grams of paste

[service parts 440037S000] to surface (A) of the joint sub assembly of the driveshaft(s) as per the ESM.

CAUTION: Apply paste to cover the entire flat surface of the joint sub-assembly of the driveshaft.

88. Carefully reinstall the driveshaft using protector [use SST: KV38107900 or a suitable equivalent] to prevent damage to the oil seal.

Slide the driveshaft sliding joint and tap with a hammer to install securely.

CAUTION: Check that the circular clip is completely engaged.

89. Fit a new bearing plate and tighten fixings (A & B) to 25Nm. Ensure notch (C) on the bearing plate is located at the uppermost

position on the underside of the bearing support. [see illustration below]

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90. Fit the splined end of the driveshafts into the steering knuckle/wheel hub assembly at both the left and the right hand side.

91. Support the rear end of the front suspension member assembly on a hydraulic transmission jack as per removal process. Support the

front suspension member assembly with 2 people and carefully manoeuvre it under the vehicle.

92. Raise the front suspension member into position. Ensure that the steering gear shaft is correctly inserted through the rubber boot into

the passenger campartment.

93. Fit the front mounting bolts by hand to support the front end of the front suspension member. Use the paint marks to ensure that the

rebound stopper rubber and insulator are correctly fitted.

94. Temporarily fit the rear mounting bolts of the front suspension member (by hand) to support the front suspension member fully.

95. Reposition the hydraulic transmission jack to allow the member stay to be fitted at the rear of the front suspension member.

96. Remove in turn the rear mounting bolts of the front suspension and position the member stay and refit the rear mounting bolts. Ensure

that the rebound stopper is correctly fitted with the protrusion aligned with the holes in the member stay.

97. Fit the remaining bolts of the member stay ensuring that the front suspension member is positioned centrally. Temporarily tighten the

mounting bolts in the order given below. [Note all bolts of the front suspension member will be torque tightened under unladen conditions

with the tyres on level ground as part of repair step 114. Temporary tighening only is required at this stage.].

98. Refit the rear torque rod mount and torque tighten bolts to 80Nm.

99. Position the rear toque rod bracket and torque rod. Fit bolt and torque tighten to 155Nm.

100. Refit the rubber mounts of the exhaust system.

101. Lower vehicle on lift.

102. Open driver's door.

103. Engage the lower end of the intermediate steering shaft onto the shaft of the steering gear ensuring that the plastic guide is

correctly fitted.

104. Refit the bolt and torque tighten to 50Nm

105. Re-install the carpet trim cover plate on the floor and secure it with plastic trim clips.

106. Lift vehicle and continue with re-assembly at each wheel station, re-connect the steering knuckle onto the lower ball joint at both

sides. Refit the bolt and temporarily secure with a new nut.

107. Refit the upper end of stabilizer connecting rod to the strut assembly. Torque tighten the nut fixing to 81Nm.

108. Refit the steering arm ball joint into the steering knuckle. Fit a new retaining nut and torque tighten to 34.4Nm.

109. Torque tighten the lower ball joint bolt fixing of the steering knuckle to 55Nm.

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110. Clean the mating surface of the wheel hub lock nut and wheel hub assembly.

CAUTION: Never apply lubricating oil to these mating surfaces.

111. Fit a new wheel hub nut and torque to range 180-185Nm.

112. Install the adjusting cap (2) and fit new cotter pin (1) and securely bend the basal portion of cotter pin to prevent rattles [see

illustration below].

113. Refit the road wheel and torque tighten the wheel nuts to 112Nm.

114. Lower vehicle on lift and perfom the final tightening of all suspension parts under unladen vehicle condition with the tyres on level

ground.

NOTE: Bolts should be slackened before the final toque tightening operation is performed.

115. Working within the engine bay, reconnect the harness connector of the DPF upstream exhaust A/F ratio sensor.

116. Refit the turbocharger heatshield and torque tighten the fixings (3 bolts) to 8Nm.

117. Reclip the fuel pipe plastic bracket.

118. Ensure the o-ring seals of the low pressure flexible airconditioning system pipe are replaced with new parts. Lubricate the o-ring seals

with compressor oil before fitment.

119. Refit the low pressure air conditioning system pipework and torque tighten bolt fixings to 13.7Nm.

120. Connect the airconditioning system to approved recovery/recycling equipment and conduct a leakage test before refilling the

airconditioning system with refrigerant in accordance with the equipment manufacturer's refill process.

121. Refill the gearbox oil to correct the level.

122. Connect the negative and positive battery terminals of the 12V battery.

123. Switch on the engine and check for correct operation of the air conditioning system.

124. With the engine running, check the exhaust tube joints for gas leakage and unusual noises.

125. Check (and where necessary adjust) the steering geometry for the vehicle due to the removal of the front suspension member

assembly.

126. Connect vehicle to Consult 3+ and perform "AFTER DPF REPLACEMENT" operation detailed within "WORK SUPPORT" of "ENGINE" in

order to clear all DPF data values stored in the ECM.

END OF REPAIR - REPLACE DPF