Nissan Note (Versa Note) Teardown (Part 2)

Drive unit and supercharger

2014/09/30

Summary

Nissan Note
Preliminary teardown of Nissan Note (Versa Note) performed on August 22, 2014
* Click on the photo for a larger image.

 The Nissan Note teardown was conducted in August 2014 by the Automotive Technology Innovation Center of the Hiroshima Industrial Promotion Organization. The teardown of the major safety technologies, such as the Around View Monitor with Moving Object Detection (MOD) function and emergency braking, and the advanced driver assistance systems is reported in Nissan Note (Versa Note) Teardown (Part 1).

 This report (Part 2) describes teardown of the supercharger, engine, and the Xtronic CVT with auxiliary gearbox. It focuses specifically on the air flow to the engine, the supercharger drive method, and engine components. In addition to the photos taken at the teardown event venue, the report will make use of the photo of the cutaway model of the CVT displayed by Jatco at the Automotive Engineering Exposition 2014 held in May.



Archived teardown reports:

Honda Accord Hybrid (Feb. 2014)
  Part 1: PCU and vehicle chassis
  Part 2: Battery and electric servo brake
  Part 3: Drive unit

Honda Fit Hybrid (Dec. 2013)
  Part 1: Battery components & brake system
  Part 2: Engine and transmission

Toyota Aqua (Prius c) (Nov. 2012)
  Part 1: Part suppliers and battery components
  Part 2: Hybrid systems behind the 35.4km/liter (53 mpg city) car

Nissan Leaf
  Part 1: Benchmarking systems and components for EV (Mar. 2012)
  Part 2: Main components disassembled (Sep. 2012)
  Part 3: Body cutaway (Nov. 2012)

Engine  1.2-liter (1,198cc) inline 3-cylinder direct-injection supercharged gasoline engine (72kW/98ps maximum output, 142Nm/14.5kgf-m maximum torque) manufactured by Aichi Machine Industry, Type HR12DDR
Supercharger  Four-lobed Roots type supercharger manufactured by Eaton.
 * The 1.2-liter 3-cylinder engine has smaller displacement than the 1.5-liter 4-cylinder engine that is used in the previous Nissan Note. This leads to higher fuel efficiency and lower travelling performance. The supercharger is used to make up for the poorer driving performance.
 * When compared to the turbocharger, the supercharger responds faster to the accelerator pedal operation and can be engaged and disengaged by a clutch.
CVT  Xtronic CVT with auxiliary gearbox manufactured by Jatco.

(Note) A supercharger takes power from the engine's crankshaft to drive its compressor. A turbocharger takes off power from the engine's exhaust gas to drive the turbine connected to the compressor.



Before disassembly

 

Before disassembly Before disassembly
A top view of the engine room. The white arrow points to the air cleaner by ROKI, the red arrow to the intake manifold, the blue arrow to the start-stop system battery by Shin-Kobe Electric Machinery, and the yellow arrow to the transmission ECU by Hitachi Automotive Systems. The green arrow points to the plastic air intake duct by Excell Corporation that interconnects the supercharger intercooler, intake manifold and air control valve. A rear bottom view of the vehicle. The white arrow points to the fuel tank by Inergy Automotive Systems, the red arrow to the pre-silencer by Futaba Industrial, the blue arrow to the silencer also by Futaba Industrial, and the yellow arrow to the catalytic converter. The fuel tank and exhaust pipe are positioned in the same layout as in the Nissan March that shares the platform.

 

 



Drive unit

 

Drive unit
Drive unit Drive unit
A front right view of the engine room after  the hood and bumper have been removed. The white arrow points to the supercharger intercooler and the red arrow to the air-conditioning condenser. An engine cooling radiator is hidden behind the condenser. The intercooler, condenser, and radiator are supplied by Behr. The condenser and radiator are manufactured in India. The blue arrow points to the horn by Miyamoto Electric Horn. A front view of the vehicle without the intercooler, condenser and radiator. The white arrow points to the Xtronic CVT with auxiliary gearbox in the drive unit by Jatco. The red arrow points to the engine alternator and the blue arrow points to the starter motor, both supplied by Mitsubishi Electric. The yellow arrow points to the air-conditioning compressor by Calsonic Kansei.
Drive unit Drive unit
The drive unit removed from the engine room and seen from the driver seat. The white arrow points to the Eaton supercharger and the red arrow to the exhaust manifold concealed in a silver cover. The blue arrow points to ROKI's outlet duct that interconnects the supercharger and the supercharger intercooler. The drive unit seen from the vehicle right. Two belts are used between the supercharger outlet duct and the engine. The white arrow points to the belt that drives the alternator, compressor and engine cooling water pump. The red arrow points to the supercharger drive belt (10mm wide).

 

 



Air flow when supercharger is engaged or disengaged

 

Supercharger engaged Supercharger disengaged
Supercharger engaged Supercharger disengaged
* The air flow is shown by the blue arrow. The red line shows the drive belt.
* The supercharger is engaged when acceleration is important; it is disengaged when higher fuel efficiency is important.
Air entering the air cleaner flows to the supercharger when the air control valve is closed. The supercharger drives the compressor via the drive belt to compress the air. The compressed air is cooled by the intercooler and flows to the intake manifold. Air entering the air cleaner flows to the intake manifold when the air control valve is open. The supercharger's electromagnetic clutch disengages the supercharger belt pulley and deactivates the supercharger.

 

 



Supercharger

 

Supercharger
Supercharger Supercharger
The supercharger after removed from the engine. It is fitted above the exhaust manifold in the direction shown in the left-hand photo. The right-hand photo shows the back of the supercharger. The supercharger housing is supplied by Ahresty Corporation. The white arrow points to the air control valve by Aisan Industry, the red arrow to Eaton's compressor, the green arrow to the compressor drive pulley, and the blue arrow to Gates's belt tensioner. The tensioner bearing in the belt tensioner pointed by the yellow arrow is manufactured at NSK's plant in China. The air entering the air cleaner flows to the supercharger or to the intake manifold from the port pointed by the purple arrow.

 

Air control valve Electromagnetic clutch
Air control valve Electromagnetic clutch
Aisan Industry's air control valve after removed from the supercharger. When the supercharger is disengaged, the valve opens so that the air entering the air cleaner is directed to the intake manifold. When the supercharger is engaged, the valve closes to direct the air to the supercharger. Ogura Clutch's electromagnetic clutch (pointed by the white arrow) is located between two pulleys. The red arrow points to the drive belt idler. The supercharger belt is fitted to the pulley pointed by the blue arrow (the belt is removed and not shown in the photo). The belt that connects to the engine's crankshaft is fitted to the pulley pointed by the green arrow (the belt is removed and not shown in the photo). To engage the supercharger, the pulleys pointed by blue and green arrows are meshed by the electromagnetic clutch so that the engine power is transmitted to the supercharger.

 

Compressor Outlet duct
Compressor Outlet duct
Eaton's compressor is used to compress the air. The three rods pointed by the white arrow are mated with the three holes pointed by the red arrow in the compressor's rotor. When the engine power is transmitted via the electromagnetic clutch to the supercharger, the supercharger pulley (pointed by the blue arrow) and the compressor rotor start rotating to compress the air. The compressed air is discharged through the opening pointed by the yellow arrow and flows to the outlet duct. ROKI's plastic outlet duct connects the supercharger to the intercooler. The photo shows the back of the outlet duct. The compressed air from the compressor enters the port pointed by the white arrow and is discharged from the port pointed by the red arrow. To reduce the noise caused by the supercharger during operations, a hollow cavity is provided in the outlet duct pointed by the blue arrow. The outlet duct has internal diameter of 80 to 90mm.

 

Intercooler Plastic air intake duct
Intercooler Plastic air intake duct
Behr's supercharger intercooler. Air is compressed by the supercharger and becomes hot. It is cooled by the intercooler before it flows to the intake manifold. Excell's plastic air intake duct. The white arrow points to the port that connects to the supercharger intercooler. The red arrow points to the port that connects to the intake manifold. The blue arrow points to the port that connects to the air control valve. The yellow arrow points to the air-flow meter supplied by Hitachi Automotive Systems.

 

 



Engine and related components

 

Engine
Engine Engine
A top view of the engine without the air cleaner and intake manifold. The driver's seat is positioned at the top of the photo. The white arrow points to the ignition coil by Hitachi Automotive Systems Hanshin. The red arrow points to Denso's fuel injection device and the blue arrow to the EGR valve by Mitsubishi Electric. The drive unit without the CVT, alternator and compressor as seen from the front right of the vehicle. The white arrow points to the space where the starter motor was mounted before removal. The red arrow points to the engine cooling water pump by Magna.
Engine Engine
A view of the engine as seen from the left side of the vehicle where the CVT is installed. The exhaust manifold and supercharger are removed. The flywheel pointed by the white arrow is 265mm in diameter. The red arrow points to the EGR valve by Mitsubishi Electric. The blue arrow points to the high-pressure fuel tank of Denso's direct-injection system concealed under the cylinder head cover. A view of the engine without the cylinder head cover and chain case as seen from the driver seat. Two chains are connected to the crankshaft to drive the camshaft and the engine oil pump respectively. The white arrow points to the engine oil pump (not visible in the photo).

 

Cylinder head Cylinder block
Cylinder head Cylinder block
A view of the cylinder head as seen from the cylinder block side. The two upper valves in each cylinder are the intake valves, the lower two are the exhaust valves. Valves are approximately 100mm long. A view of the cylinder block without the cylinder head and cam chain. The white arrow points to the engine oil pump. The red arrow points to the area where the engine cooling water pump was installed before removal.

 

Intake manifold Fuel injector
Intake manifold Fuel injector
The intake manifold is seen with Denso's swirl control valve in the intake port. The red arrow points to the swirl actuator that controls the swirl control valve. The white arrow points to the throttle body by Hitachi Automotive Systems. The intake port of the throttle body is 55mm in diameter. Denso's direct fuel injection system. It consists of the high-pressure fuel pump (pointed by the white arrow), high-pressure injector (red arrow) and fuel pressure sensor (blue arrow). Only one injector is shown on the photo but the Note's 3-cylinder engine actually has three injectors.

 

Engine oil pump Starter motor
Engine oil pump Starter motor
Inside of the engine oil pump. The pump is driven via chain connected to the crankshaft. The starter motor by Mitsubishi Electric. The pinion gear is located where pointed by the arrow. It drives the ring gear of the flywheel to start the engine.

 

Alternator Compressor
Alternator Compressor
The alternator by Mitsubishi Electric uses the regenerative energy from deceleration to charge the battery. It suppresses electric power generation in non-deceleration mode. The air conditioning compressor by Calsonic Kansei. Its pulley is 95mm in diameter.

 

Canister Engine Management System (EMS)
Canister Engine Management System (EMS)
Mahle's activated carbon canister is fitted in the front occupant's side of the engine room. The Engine Management System (EMS) by Hitachi Automotive Systems is fitted in the front occupant's side of the engine room.

 

 



Xtronic CVT with auxiliary gearbox

 

CVT
CVT CVT
A view of the CVT removed from the drive unit and seen from the engine side. The part pointed by the white arrow is meshed with the driveshaft to drive the front wheels. The red arrow points to the rotation sensor of the secondary (driven) pulley. The CVT housing is supplied by Ahresty. A view of the CVT seen from the vehicle left. The white arrow points to the transmission oil pump by JTEKT, the red arrow to the rotation sensor of the primary (drive) pulley, the blue arrow to the range switch, the green arrow to the rotation sensor of the secondary (driven) pulley, and the yellow arrow to the vehicle speed sensor.

 

CVT cutaway model
CVT cutaway model CVT cutaway model
The cutaway model of the CVT with an auxiliary gearbox (named CVT7 by Jatco) exhibited by Jatco at the Automotive Engineering Exposition held in May 2014. The white arrow points to the primary (drive) pulley, the red arrow to the secondary (driven) pulley, and the blue arrow to the (2-speed) auxiliary gearbox. The use of the auxiliary gearbox has made it possible to increase the transmission gear ratio while reducing the pulley size.

 

Transmission ECU Transmission oil pump
Transmission ECU Transmission oil pump
Transmission ECU supplied by Hitachi Automotive Systems is located near the front occupant's seat in the engine room. It is fitted in contact with the battery. JTEKT's transmission oil pump removed from the CVT.

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