Juke F15 (2012 year). Service Repair Manual — part 180

EM-28

< REMOVAL AND INSTALLATION >

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INTAKE MANIFOLD

INTAKE MANIFOLD

Exploded View

INFOID:0000000006337252

1.

Clamp

2.

Water hose

3.

PCV hose

4.

Clamp

5.

Gasket

6.

Intake manifold

7.

Clamp

8.

Vacuum hose

9.

Vacuum gallery assembly

10. Clamp

11.

EVAP hose

12. EVAP service port valve

13. EVAP hose

14.

EVAP canister purge volume control
solenoid valve

15. Bracket

16. Clamp

17. Bracket

18. EVAP hose

19. Clamp

20. EVAP tube

21. EVAP hose

22. Clamp

23. Clamp

24. Water hose

25. Electric throttle control actuator

26. Gasket

A.

To turbocharger

B.

To centralized under-floor piping

C.

To recirculation valve hose

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA4306GB

INTAKE MANIFOLD

EM-29

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Removal and Installation

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REMOVAL

1.

Remove engine cover. Refer to

EM-25, "Exploded View"

.

2.

Pull out oil level gauge.

CAUTION:

Cover the oil level gauge guide openings to avoid entry of foreign materials.

3.

Disconnect turbocharger boost sensor (with intake air temperature sensor 2) harness connector. Refer to

EM-31, "Exploded View"

.

4.

Remove air inlet tube assembly. Refer to

EM-31, "Exploded View"

.

5.

Disconnect water hoses from electric throttle control actuator as follows:
• Attach plug to prevent engine coolant leakage when engine coolant is not drained. Refer to

CO-11,

"Draining"

.

CAUTION:

Perform this step when the engine is cold.
NOTE:
This step is not required when removing only intake manifold.

6.

Disconnect electric throttle control actuator harness connector.

7.

Remove electric throttle control actuator.

CAUTION:

• Handle carefully to avoid any shock to electric throttle control actuator.
• Never disassemble electric throttle control actuator.

8.

Disconnect EVAP canister purge volume control solenoid valve harness connector, and them remove
bracket with EVAP canister purge volume control solenoid valve.

9.

Remove vacuum gallery.

10. Disconnect PCV hose (intake manifold side).

11. Remove intake manifold (1) with the following procedure.

• Loosen and remove intake manifold mounting bolt (A).

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

NOTE:
Disregard the numerical order No.6 in removal.

CAUTION:

Cover engine openings to avoid entry of foreign materi-
als.

INSTALLATION

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

Intake Manifold

1.

Check if gasket is not dropped from the installation groove of intake manifold.

2.

Install intake manifold with the following procedure:

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: Engine front

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EM-30

< REMOVAL AND INSTALLATION >

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INTAKE MANIFOLD

a.

Tighten in numerical order as shown in the figure.

NOTE:
• Tighten bolt the No.1 in two steps.
• The numerical order No.6 shows the second step.

3.

Install in the reverse order of removal after this step.

Electric Throttle Control Actuator

• Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
• Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the elec-

tric throttle control actuator. Refer to

EC-135, "Work Procedure"

.

• Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing

electric throttle control actuator. Refer to

EC-135, "Work Procedure"

and

EC-136, "Work Procedure"

.

: Engine front

JPBIA4356ZZ

CHARGE AIR COOLER

EM-31

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CHARGE AIR COOLER

Exploded View

INFOID:0000000006337254

Removal and Installation

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REMOVAL

1.

Remove front bumper. Refer to

EXT-12, "Exploded View"

.

2.

Remove radiator core support upper. Refer to

DLK-149, "MR16DDT : Exploded View"

.

3.

Remove air inlet hose between air inlet tube and charge air cooler.

1.

Air inlet tube assembly

2.

Air inlet tube bracket

3.

Clamp

4.

Air inlet hose

5.

Gasket

6.

Turbocharger

7.

Mounting rubber

8.

Charge air cooler

9.

Air inlet tube assembly

10. Air inlet tube bracket

11.

Air inlet hose

12. Air inlet tube assembly

13.

Turbochager boost sensor
(with intake air temperture sensor 2)

14. Grommet

15. Grommet

16. Air inlet hose

17. Clamp

18. Recirculation valve

19. Clamp

20. Vacuum hose

21. Gasket

A.

To vacuum gallery assembly

B.

To electric throttle control actuator

C.

To turbocharger

: Vehicle front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA4307GB

EM-32

< REMOVAL AND INSTALLATION >

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CHARGE AIR COOLER

4.

Remove charge air cooler (1).

CAUTION:

• Avoid interference between the charge air cooler and radi-

ator.

• When removing charge air cooler, close opening on turbo

charger and intake manifold with shop cloth or other suit-
able material.

INSTALLATION

Install in the reverse order of removal paying attention to the following points:
• Apply a neutral detergent (fluid) to the joint between hoses and pipes (oil is not permissible).
• Pay attention to identification mark and direction.
• When installing air inlet hoses and tubes. Refer to

EM-31, "Removal and Installation"

.

Inspection

INFOID:0000000006337256

INSPECTION AFTER REMOVAL

1.

Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it
dry.

2.

Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler in necessary.
• Be careful not to deform core fins.
• For cleaning procedure of charge air cooler core, refer to

CO-19, "Inspection"

.

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CATALYST

EM-33

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CATALYST

2WD

2WD : Exploded View

INFOID:0000000006430453

2WD : Removal and Installation

INFOID:0000000006430454

REMOVAL

1.

Remove engine cover. Refer to

EM-25, "Exploded View"

.

2.

Remove cowl top extension. Refer to

EXT-20, "Exploded View"

.

3.

Remove front tube. Refer to

EX-5, "Exploded View"

.

4.

Remove A/F sensor 1.
• Using heated oxygen sensor wrench [SST: KV10117100], remove A/F sensor 1.

CAUTION:

Handle A/F sensor 1 carefully and avoid impacts.

5.

Remove catalyst convertor shroud upper.

6.

Remove bolts and nut of catalyst convertor turbocharger side.

7.

Remove support bracket (RH).

8.

Remove drive shaft insulator. Refer to

9.

Remove catalyst convertor.

JPBIA4321GB

1.

A/F sensor 1

2.

Catalyst convertor shroud upper

3.

Gasket

4.

Catalyst

5.

Catalyst convertor support bracket rear

6.

Catalyst convertor bracket (RH)

A.

To exhaust system

Engine front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

EM-34

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CATALYST

INSTALLATION

1.

Install catalyst convertor with the following procedure.
• Tighten in numerical order as shown in the figure.
- Install catalyst convertor (base on stud position 1).
- Temporary assemble 2 (no priority).
- Temporary assemble 3, 4.
- Tightening 5, 6 and 7.
- Tightening again 8, 9 and 10.
- Temporary assemble 11.
- Tightening 12,13,14,and 15.

2.

Install in the reverse order of removal after this step.

4WD

4WD : Exploded View

INFOID:0000000006430461

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CATALYST

EM-35

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4WD : Removal and Installation

INFOID:0000000006430462

REMOVAL

1.

Drain engine coolant. Refer to

CO-11, "Draining"

.

2.

Remove engine cover. Refer to

EM-25, "Exploded View"

.

3.

Remove cowl top extension. Refer to

EXT-20, "Exploded View"

.

4.

Remove front tube. Refer to

EX-5, "Exploded View"

5.

Remove A/F sensor 1.

6.

Remove catalyst convertor shroud upper.

7.

Remove bolts and nut of catalyst convertor turbocharger side.

8.

Remove drive shaft insulator.

9.

Remove support bracket (RH).

10. Move catalyst convertor.

11. Remove turbocharger. Refer to

EM-36, "Exploded View"

.

12. Remove catalyst convertor.

INSTALLATION

1.

Install catalyst convertor with the following procedure.
• Tighten in numerical order as shown in the figure.
- Install catalyst convertor (base on stud position 1).
- Temporary assemble 2 (no priority).
- Temporary assemble 3, 4.
- Tightening 5, 6 and 7.
- Tightening again 8, 9 and 10.
- Temporary assemble 11.
- Tightening 12,13,14,and 15.

2.

Install in the reverse order of removal after this step.

1.

A/F sensor 1

2.

Catalyst convertor shroud upper

3.

Gasket

4.

Heated oxygen sensor 2

5.

Catalyst convertor upport bracket rear

6.

Catalyst convertor

7.

Catalyst convertor support bracket (RH)

A.

To exhaust system

Engine front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA4371GB

EM-36

< REMOVAL AND INSTALLATION >

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TURBOCHARGER

TURBOCHARGER

Exploded View

INFOID:0000000006337257

Removal and Installation

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REMOVAL

1.

Heat insulator

2.

Actuator hose

3.

Clamp

4.

Turbocharger inlet tube

5.

Gasket

6.

Gasket

7.

Clamp

8.

Oil outlet hose

9.

Oil return pipe

10. Oil supply tube

11.

O-ring

12. O-ring

13. Turbocharger

14. Eye bolt

15. Gasket

16. Oil supply tube

A.

To EVAP canister purge volume con-
trol solenoid valve

B.

To air inlet hose

C.

To PCV hose

D.

To air duct

E.

To air inlet tube assembly

F.

To catalyst convertor

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA4308GB

TURBOCHARGER

EM-37

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1.

Drain engine coolant. Refer to

CO-11, "Draining"

.

2.

Remove engine cover. Refer to

EM-25, "Exploded View"

.

3.

Remove air cleaner cover assembly and air cleaner body assembly. Refer to

EM-26, "Exploded View"

.

4.

Remove air inlet tube assembly. Refer to

EM-31, "Exploded View"

.

5.

Remove cowl top extension. Refer to

EXT-20, "Exploded View"

.

6.

Disconnect heated oxygen sensor 2 harness connector.

7.

Remove front tube. Refer to

EX-5, "Exploded View"

.

8.

Remove catalyst convertor. Refer to

EM-33, "2WD : Exploded View"

(2WD models) or

EM-34, "4WD :

Exploded View"

(4WD models).

9.

Remove turbocharger assembly as follows:

a.

Remove heat insulator.

b.

Remove oil supply tube.

c.

Remove mounting nuts of turbocharger.

CAUTION:

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

INSTALLATION

Install in the reverse order of removal.
NOTE:
Apply LOCTITE FRENETANCH or equivalent to the threads of the turbocharger oil inlet pipe union to the cyl-
inder head.

Inspection

INFOID:0000000006337259

INSPECTION AFTER REMOVAL

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 failure:

INSPECTION AFTER INSTALLATION

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

JPBIA4359ZZ

A.

Check for leakage

Suction side

: Between turbocharger and air cleaner

Exhaust side

: Between turbocharger and outlet duct

EM-38

< REMOVAL AND INSTALLATION >

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EXHAUST MANIFOLD

EXHAUST MANIFOLD

Exploded View

INFOID:0000000006337260

Removal and Installation

INFOID:0000000006337261

REMOVAL

1.

Drain engine coolant. Refer to

CO-11, "Draining"

.

2.

Remove turbocharger. Refer to

EM-36, "Exploded View"

.

3.

Remove catalyst convertor. Refer to

EM-33, "2WD : Exploded View"

(2WD models) or

EM-34, "4WD :

Exploded View"

(4WD models).

4.

Remove exhaust manifold cover.

5.

Remove exhaust manifold.

JPBIA4312GB

1.

Stud bolt

2.

Exhaust manifold cover

3.

Exhaust manifold

4.

Gasket

Engine front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

EXHAUST MANIFOLD

EM-39

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

NOTE:
Disregard the numerical order No. 9 to 12 in removal.

6.

Remove gasket.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

INSTALLATION

1.

Install gasket to cylinder head as shown in the figure.

2.

Install exhaust manifold with the following procedure:

a.

Tighten nuts in numerical order as shown in the figure.

NOTE:
• Tighten nuts the No.1 to No.4 in two steps.
• The numerical order No.9 to No.12 shows the second step.

3.

Install remaining parts in the reverse order of removal.

Inspection

INFOID:0000000006337262

INSPECTION AFTER REMOVAL

Surface Distortion

• Using feeler gauge (A) and straightedge (B), check the surface dis-

tortion of exhaust manifold mating surface in each exhaust port
and entire part.

• If it exceeds the limit, replace exhaust manifold.

: Engine front

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: Engine front

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: Engine front

JPBIA4360ZZ

Limit

: Refer to

EM-130, "Exhaust Manifold"

.

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EM-40

< REMOVAL AND INSTALLATION >

[MR16DDT ]

OIL PAN (LOWER)

OIL PAN (LOWER)

Exploded View

INFOID:0000000006430456

1.

O-ring

2.

Oil pan (upper)

3.

Oil level gauge guide

4.

O-ring

5.

Oil level gauge

6.

Oil pump drive chain

7.

Crankshaft sprocket

8.

Oil pump sprocket

9.

Oil pump chain tensioner

10. Oil pump

11.

Drain plug

12. Drain plug washer

13. Oil pan (lower)

14. Oil filter

15. Connector bolt

16. Clamp 17. Water

hose

18. Oil

cooler

19. Crankshaft position sensor

20. Oil level sensor

21. Rear oil seal

A.

Refer to

LU-11

B.

Oil pan side

C.

To thermostat housing (M/T models)
To CVT oil warmer (CVT models)

D.

Oil pan side

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA4309GB

OIL PAN (LOWER)

EM-41

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Removal and Installation

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REMOVAL

1.

Drain engine oil. Refer to

LU-9, "Draining"

.

2.

Remove oil pan (lower) with the following procedure:

a.

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

NOTE:
Disregard the numerical order No.7 and No.11 in removal.

b.

Insert seal cutter [SST: KV10111100 (J-37228)] (A) between oil
pan (upper) and oil pan (lower).

CAUTION:

• Be careful not to damage the mating surface.
• Never insert a screwdriver. This damages the mating sur-

faces.

c.

Slide the seal cutter [SST: KV10111100 (J-37228)] by tapping on
the side of tool with a hammer.

d.

Remove oil pan (lower).

INSTALLATION

1.

Install oil pan (lower) as follows:

a.

Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Also remove old liquid gasket from mating surface of oil pan

(upper).

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

CAUTION:

Never scratch or damage the mating surface when cleaning
off old liquid gasket.

: Sealing point

: Should be lubricated with oil.

: Engine front

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JPBIA4366ZZ

EM-42

< REMOVAL AND INSTALLATION >

[MR16DDT ]

OIL PAN (LOWER)

b.

Apply a continuous bead of liquid gasket (A) with a 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 liquid gas-
ket application.

c.

Tighten bolts in numerical order as shown in the figure.

NOTE:
• Tighten bolts the No.1 and No.2 in two steps.
• The numerical order No.7 and No.11 shows the second steps.

2.

Install oil pan drain plug.
• Refer to the figure of components of former page for installation direction of drain plug washer. Refer to

EM-99, "Exploded View"

.

3.

Install in the reverse order of removal after this step.

Inspection

INFOID:0000000006337265

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-8, "Inspection"

.

2.

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

3.

Stop engine and wait for 10 minutes.

4.

Check the engine oil level again. Refer to

LU-8, "Inspection"

.

1

: Oil pan (lower)

b

: 7.5-9.5mm (0.295 - 0.374 in)

c

:

φ

4.0 - 5.0 mm (0.157 - 0.197 in)

: Engine outside

JPBIA4367ZZ

: Engine front

JPBIA4364GB

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

EM-43

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HIGH PRESSURE FUEL PUMP AND FUEL HOSE

Exploded View

INFOID:0000000006337266

CAUTION:

Never remove or disassemble parts unless instructed as shown in the figure.

Removal and Installation

INFOID:0000000006337267

REMOVAL

WARNING:

• Be sure to read

EM-7, "Precaution for Handling High Pressure Fuel System"

when working on the

high pressure fuel system.

• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO

2

fire extinguisher.

• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
• To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1.

Release fuel pressure. Refer to

EC-140, "Work Procedure"

.

2.

Remove engine cover. Refer to

EM-25, "Exploded View"

.

3.

Remove fuel pump connector protector, and remove high pressure fuel pump insulator.

1.

High pressure fuel pump insulator

2.

High pressure fuel pump

3.

O-ring

4.

Valve lifter

5.

Fuel tube assembly

6.

Bracket

7.

Fuel pump connector protector

8.

Fuel feed hose

A.

To centralized under-floor piping

B.

To fuel tube assembly

: Engine front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA4310GB