Juke F15 (2012 year). Service Repair Manual — part 190
EM-188
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TIMING CHAIN
b.
Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to front cover as shown in the figure.
Use Genuine Liquid Gasket or equivalent.
c.
Tighten bolts in the numerical order as shown in the figure.
d.
After all bolts are tightened, retighten them to specified torque in
numerical order as shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to
surface.
8.
Insert crankshaft pulley by aligning with crankshaft key.
• When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Install protecting front oil seal lip section from any damage.
9.
Tighten crankshaft pulley bolt with the following procedure:
• Secure crankshaft pulley with a pulley holder (commercial service tool), and tighten crankshaft pulley
bolt.
a.
Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b.
Tighten crankshaft pulley bolt.
1
: Front cover edge
A
: Liquid gasket application area
b
: 4.0 - 5.6 mm
c
: Liquid gasket application area [
φ
3.0 - 4.0 mm (0.12 - 0.16 in)]
JPBIA4146ZZ
JPBIA4139ZZ
TIMING CHAIN
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c.
Put a paint mark (B) on crankshaft pulley, mating with any one of
six easy to recognize angle marks (A) on crankshaft bolt flange
(1).
d.
Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark.
10. Check that crankshaft turns smoothly by rotating by hand clockwise.
11. Install in the reverse order of removal.
Inspection
INFOID:0000000006449915
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks (A) and any excessive wear (B) at link plates and
roller links of timing chain. Replace timing chain if necessary.
INSPECTION AFTER INSTALLATION
Inspection for Leakage
The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.
• 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-13, "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.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise
will stop after hydraulic pressure rises.
• Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including 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:
: 35.0 N·m (3.6 kg-m, 26 ft-lb)
PBIC3726E
PBIC3169J
Items
Before starting engine
Engine running
After engine stopped
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
EM-190
< REMOVAL AND INSTALLATION >
[HR16DE]
TIMING CHAIN
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
Other oils and fluid*
Level
Leakage
Level
Fuel
Leakage
Leakage
Leakage
CAMSHAFT
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Exploded View
INFOID:0000000006449916
Removal and Installation
INFOID:0000000006449917
CAUTION:
1.
Camshaft bracket (No. 2 to 5)
2.
Camshaft bracket (No. 1)
3.
Camshaft sprocket (EXH)
4.
Exhaust valve timing control sole-
noid valve
5.
O-ring
6.
Camshaft sprocket (INT)
7.
Plug (EXH)
8.
Washer (EXH)
9.
Oil filter (for exhaust valve timing control
solenoid valve)
10. Cylinder head
11.
Oil filter (for intake valve timing
control solenoid valve)
12.
Washer (INT)
13. Plug (INT)
14. O-ring
15. Intake valve timing control solenoid
valve
16. Bracket
17. Valve lifter
18. Camshaft (INT)
19. Camshaft (EXH)
A.
Tightening must be done following the installation procedure.
Refer to
: Always replace after every disassembly.
: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
: Should be lubricated with oil.
: Select with proper thickness.
JPBIA4096GB
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CAMSHAFT
The rotation direction indicated in the text indicates all directions seen from the engine front direction.
REMOVAL
1.
Hold the bottom surface of the engine with a jack to remove the right engine mount assembly and the
insulator. Refer to
2.
Remove rocker cover. Refer to
3.
Remove camshaft position sensor from rear end of cylinder head.
CAUTION:
Handle it carefully and avoid impacts.
4.
Place cylinder No. 1 at TDC of its compression stroke with the following procedure.
a.
Rotate crankshaft pulley (2) clockwise and align TDC mark
(without paint mark) (A) to timing indicator (1) on front cover.
b.
Check that the matching marks on each the camshaft sprockets
are in the position as shown in the figure.
• If not, rotate crankshaft pulley one more turn to align matching
marks to the positions in the figure.
c.
Paint matching marks (A) on the timing chain links
5.
Remove crankshaft pulley. Refer to
6.
Remove front cover. Refer to
.
7.
Secure the plunger of chain tensioner in the fully compressed position with the following procedure. And
then, loosen the timing chain tension.
a.
Fully push down the lever (B) of chain tensioner (2) from the
plug hole, and then insert the stopper pin (A) into the body side
hole and secure the lever at the lowest position.
• The tab is released by fully pushing the lever down. As a
result, the plunger (1) can be moved.
NOTE:
Hexagonal wrench [2.5 mm (0.098 in)] is used for a stopper pin
as an example.
CAUTION:
The stopper pin must use a shape that cannot fall in the
front cover when dropping out.
B
: White paint mark (Not use for service)
PBIC3673E
1.
: Timing chain
2.
: Camshaft sprocket (EXH)
3.
: Camshaft sprocket (INT)
A
: Matching mark (Peripheral groove)
B
: Matching mark (Stamp)
C
: Matching mark (Peripheral groove)
C : Front cover has been omitted
JPBIA4138ZZ
PBIC3676E
CAMSHAFT
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b.
Turn the crankshaft pulley (2) counterclockwise with the cam-
shaft (EXH) (1) fixing. Apply the tension to the timing chain, and
then push the plunger of into the inside of chain tensioner.
CAUTION:
Hold the camshaft hexagonal part (A), and then secure the
camshaft.
c.
Pull out the stopper pin (A) of chain tensioner (2) side from plug
hole. Lift the lever (B) up to align its hole position with the hole of
the body.
• When the lever hole (C) is aligned with the body hole position,
the plunger (1) is fixed.
• When the protrusion parts of the plunger ratchet and the tab
face each other, both hole positions are not aligned. At that
time, correctly engage them and align these hole positions by
slightly moving the plunger.
d.
Insert the stopper pin into the body hole through the lever hole, and then fix the lever at the upper position.
8.
Remove timing chain.
9.
Remove camshaft sprocket (EXH) (1).
CAUTION:
• Hold the camshaft hexagonal part (A), and then secure the
camshaft.
• Never rotate crankshaft and camshaft separately, so as
not to contact valve with piston in the following steps.
NOTE:
The timing chain with the front cover installed is not disengaged
from the crankshaft sprocket and it is not dropped into the front
cover. Therefore, the timing chain tension holding device is not
necessary.
10. Turn the camshaft sprocket (INT) to the most advanced position.
CAUTION:
Installation and removal of the camshaft sprocket (INT) must be done in the most advanced posi-
tion for the following reasons, so check that you follow the procedure exactly.
• The sprocket (C) and vane (camshaft coupling) (B) are
designed to spin and move within the range of a certain
angle.
• With the engine stopped and the vane in the most
retarded angle, it will not spin because it is locked to the
sprocket side by the internal lock pin (A).
• If the camshaft sprocket mounting bolts are turned in the
situation described above, the lock pin will become dam-
aged and cause malfunctions because of the increased
horizontal load (cutting force) on the lock pin.
• Put the camshaft sprocket (INT) in the most advance position with the following procedure.
PBIC3677E
D : Front cover has been omitted
PBIC3772E
JPBIA4160ZZ
PBIC3679E
EM-194
< REMOVAL AND INSTALLATION >
[HR16DE]
CAMSHAFT
a.
Remove camshaft bracket (No. 1) (1).
• Loosen the bolts in several steps, and then remove them.
b.
Apply the following air pressure to the No. 1 journal oil hole (A)
of camshaft (INT) (1) shown in the figure using an air gun.
• Apply the air pressure into the oil hole on the second groove
from the front of camshaft thrust (B).
• Proceed all the way through step “e” with the air pressure on.
• Attach the rubber nozzle (B) narrowed to the top of the air gun
(A) to prevent air leakage from the oil hole. Securely apply the
air pressure to the oil hole.
CAUTION:
• There are other oil holes in the side grooves. Never use
the incorrect oil holes.
• Be sure not to damage the oil path with the tip of the air
gun.
• Wipe all the oil off the air gun to prevent oil from being
blown all over along with the air, and the area around the
air gun should be wiped with a rag when applying air
pressure. Eye protection should be worn as needed.
NOTE:
The air pressure is used to move the lock pin into the disengage position.
c.
Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alter-
natively.
• Finally rotate the sprocket of the camshaft sprocket (INT) counterclockwise [the direction shown by the
arrow (
)].
• Perform the work while applying the air pressure to the oil hole.
• If the lock pin is not released by hands, tap the camshaft
sprocket (INT) lightly with a plastic hammer (A).
• If the camshaft sprocket (INT) is not rotated counterclockwise
even if the above procedures are performed, check the air
pressure and the oil hole position.
: Engine front
PBIC3680E
Pressure
: 300 kPa (3.0 bar, 3.1 kg/cm
2
, 44psi) or more
JPBIA4150ZZ
JPBIA4151ZZ
JPBIA4152ZZ
CAMSHAFT
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d.
While doing the above, once you hear a click (the sound of the
internal lock pin disengaging) from inside the camshaft sprocket
(INT), start turning the camshaft sprocket (INT) in the counter-
clockwise direction in the most advanced angle position.
• Keep the air pressure on.
• If there is no click, as soon as the vane-side (camshaft side)
starts moving independently of the sprocket, the lock pin has
become disengaged.
• Check that it is in the most advanced angle position by seeing
if the stopper pin groove (A) and the stopper pin hole (B) are matched up as shown in the figure.
e.
Complete the applying procedure of air pressure and the holding procedure of camshaft (INT).
f.
Insert the stopper pin (A) into the stopper pin holes in the cam-
shaft sprocket (INT) and lock in the most advanced angle posi-
tion.
CAUTION:
No load is exerted on the stopper pin (spring reaction, etc.).
Since it comes out easily, secure it with tape (B) to prevent
it from coming out.
NOTE:
The stopper pin in the figure shows one example of a hexagonal
wrench for 2.5 mm (0.098 in) [length of inserted section:
approximately15 mm (0.59 in)].
11. Remove the camshaft sprocket (INT) with the following procedure.
a.
Keeping the camshaft hexagonal part (A) still with the wrench,
loosen mounting the bolts for the camshaft sprocket (INT) (2).
CAUTION:
• Never drop stopper pin.
• Tape (C) the stopper pin (B) so it does not come out.
• Never subject it to impact by dropping.
• Never disassemble. [Never loosen the three mounting
bolts (A)].
NOTE:
While removing the camshaft sprocket (INT), if you have taken
out the stopper pin and the lock pin has been rejoined in the
most retarded angle, do the following to restore it.
i.
Install the camshaft (INT) and tighten the mounting bolts enough to prevent air from leaking out.
CAUTION:
The internal lock pin will get damaged, so keep the torque on the mounting bolts to the minimum
required to prevent air from escaping.
C
: Lock pin engaged
D
: Most advanced angle
PBIC3684E
JPBIA4153ZZ
1.
Camshaft (INT)
JPBIA4154ZZ
PBIC3691E
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< REMOVAL AND INSTALLATION >
[HR16DE]
CAMSHAFT
ii.
Apply the air pressure, disengage the lock pin, and turn the vane to the most advanced angle position.
iii.
Insert the stopper pin.
iv.
Remove camshaft sprocket (INT) from the camshaft.
12. Remove camshaft brackets (No. 2 to 5).
• Loosen bolts in several steps in the reverse of the order as
shown in the figure.
NOTE:
The camshaft bracket (No. 1) has been already removed.
13. Remove camshaft (EXH).
14. Remove camshaft (INT).
15. Remove valve lifter.
• Identify installation positions, and store them without mixing them up.
16. Remove intake valve timing control solenoid valve (1).
17. Remove the alternator and bracket, remove the plug (2), and
then remove the oil filter. Refer to
.
18. Remove exhaust valve timing control solenoid valve.
19. Remove the plug on the exhaust valve timing control solenoid valve and the oil filter.Refer to
INSTALLATION
1.
Install oil filter (1) (for intake and exhaust valve timing control
solenoid valves)
NOTE:
The figure shows the intake side as an example.
• The oil filter is assembled to the plug (3), and then install it to
the cylinder head.
2.
Install intake and exhaust valve timing controlsolenoid valves.
• Insert it straightly into the cylinder head.
• Tighten bolts after placing it completely.
3.
Install valve lifter.
• If it is reused, install in its original positions.
4.
Put a matching mark for positioning the camshaft (INT) and the camshaft sprocket (INT) with the following
procedure.
NOTE:
A
: EXH side
B
: INT side
: Engine front
PBIC3686E
PBIC3692E
2
: Washer
PBIC3695E
CAMSHAFT
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It prevents the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and
the camshaft sprocket (INT).
a.
Put the matching marks (A) on a line extending from the knock
pin position of camshaft (INT) (1) front surface.
• Put the marks on the visible position with the camshaft
sprocket installed. (The figure shows an example.)
b.
Put the matching marks on a line extending from the knock pin
hole (B) position of camshaft sprocket (INT) (2). (The figure
shows an example.)
• Put the marks on the visible position with it installed to the
camshaft.
5.
Put a matching mark for positioning the camshaft (EXH) and the camshaft sprocket (EXH) with the follow-
ing procedure.
NOTE:
It prevents the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and
the camshaft sprocket (EXH).
a.
Put the matching marks (A) on a line extending from the knock
pin position of camshaft (EXH) (1) front surface.
• Put the marks on the visible position with the camshaft
sprocket installed. (The figure shows an example.)
b.
Put the matching marks on a line extending from the knock pin
hole (B) position of camshaft sprocket (EXH) (2). (The figure
shows an example.)
• Put the marks on the visible position with it installed to the
camshaft.
6.
Install camshaft.
• Distinction between camshaft (INT and EXH) is performed with
the different shapes of rear end.
• Install camshafts to the cylinder head so that knock pins (A) on
front end are positioned as shown in the figure.
NOTE:
Though camshaft does not stop at the portion as shown in the
figure, for the placement of cam nose, it is generally accepted
camshaft is placed for the same direction of the figure.
PBIC3696E
JPBIA4155ZZ
1
: Camshaft (EXH)
2
: Camshaft (INT)
A
: Identification mark
JPBIA4156ZZ
1
: Camshaft (EXH)
2
: Camshaft (INT)
: Upper side
JPBIA4157ZZ
EM-198
< REMOVAL AND INSTALLATION >
[HR16DE]
CAMSHAFT
7.
Install camshaft brackets (No. 2 to 5) aligning the identification
marks on upper surface as shown in the figure.
• Install so that identification mark can be correctly read when
viewed from the INT side.
8.
Tighten mounting bolts of camshaft brackets in the following
steps, in numerical order as shown in the figure.
a.
Tighten No. 9 to 11 in numerical order.
b.
Tighten No. 1 to 8 in numerical order.
c.
Tighten all bolts in numerical order.
d.
Tighten all bolts in numerical order.
9.
Install the camshaft sprocket (INT and EXH) to the camshaft
(INT and EXH) with the following procedure.
a.
Refer to the matching mark (A) put according to step “4”.
Securely align the knock pin and the pin hole, and then install
them.
NOTE:
The figure shows the intake side as an example.
10. Tighten the camshaft sprocket mounting bolt (INT and EXH).
CAUTION:
Hold the camshaft hexagonal part (A), and then secure the
camshaft.
A
: EXH side
B
: INT side
: Engine front
PBIC3703E
A
: EXH side
B
: INT side
: Engine front
: 2.0 N·m (0.2 kg-m, 1 ft-lb)
: 2.0 N·m (0.2 kg-m, 1 ft-lb)
: 5.9 N·m (0.6 kg-m, 4 ft-lb)
: 10.4 N·m (1.1 kg-m, 8 ft-lb)
PBIC3686E
PBIC3700E
JPBIA4158ZZ
CAMSHAFT
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11. Install the camshaft (INT and EXH) to the camshaft sprocket
(INT and EXH) (2 and 3) while aligning the matching mark
(marked when timing chain is removed) (A) and the matching
mark (stamp) (B) of camshaft sprocket (INT and EXH).
• If the positions of knock pin and pin groove are not aligned,
move the camshaft (EXH) slightly to correct these positions.
12. Pull out the stopper pin (A), and then apply the tension to the
timing chain by rotating the crankshaft pulley clockwise slightly.
13. Pull out the stopper pin of chain tensioner.
14. Install front cover.
15. Return the camshaft sprocket (INT) in the most retarded position with the following procedure.
a.
Remove the stopper pin (A) from the camshaft sprocket (INT).
b.
Turn the crankshaft pulley (1) slowly clockwise (A) and return
the camshaft sprocket (INT) to the most retarded angle position.
1
: Timing chain
C
: Matching mark (peripheral stamp line)
JPBIA4159ZZ
1
: Plunger
2
: Chain tensioner
B
: Lever
C
: Lever hole
D
: Front cover has been omitted
PBIC3772E
B
: Tape
PBIC3685E
PBIC3704E
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CAMSHAFT
• When first turning the crankshaft the camshaft sprocket (INT)
will turn. Once it is turned more, and the vane (camshaft) also
turns, then it has reached the most retarded angle position.
• The most retarded angle position can be checked by seeing if
the stopper pin groove (A) is shifted clockwise.
• After spinning the crankshaft slightly in the counterclockwise
direction, you can check the lock pin has joined by seeing if
the vane (camshaft) and the sprocket move together.
16. Install the camshaft position sensor (PHASE) to the rear end of cylinder head.
• Tighten bolts with it seated completely.
17. Check and adjust valve clearance. Refer to
EM-148, "Inspection and Adjustment"
18. Install in the reverse order of removal.
Inspection
INFOID:0000000006449918
INSPECTION AFTER REMOVAL
Oil Filter
• Check that there is no foreign material on the oil filter (1) and check
it for clogging.
• Check the oil filter for damage.
• If there is some damage, replace the oil filter, the plug, and the
washer as a set.
Camshaft Runout
1.
Put V-block on a precise flat table, and support No. 2 and 5 jour-
nals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other
four locations.
2.
Set a dial indicator vertically to No. 3 journal.
3.
Turn camshaft to one direction with hands, and measure the
camshaft runout on the dial indicator. (Total indicator reading)
4.
If it exceeds the limit, replace camshaft.
Camshaft Cam Height
B
: Stopper pin hole
C
: Most advanced angle
D
: Lock pin engaged
PBIC3705E
PBIC3693E
Standard and Limit
: Refer to
.
PBIC2499E
CAMSHAFT
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1.
Measure the camshaft cam height with a micrometer (A).
2.
If wear exceeds the limit, replace camshaft.
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL DIAMETER
Measure the outer diameter of camshaft journal with a micrometer
(A).
CAMSHAFT BRACKET INNER DIAMETER
• Tighten camshaft bracket bolts with the specified torque. Refer to "INSTALLATION" for the tightening proce-
dure.
• Measure inner diameter (B) of camshaft bracket with a bore gauge
(A).
CAMSHAFT JOURNAL OIL CLEARANCE
• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)
• If it exceeds the limit, replace either or both camshaft and cylinder head.
NOTE:
Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder
head. Replace whole cylinder head assembly.
Camshaft End Play
1.
Install camshaft in cylinder head. Refer to
EM-191, "Removal and Installation"
for tightening procedure.
Standard and Limit
Intake
: Refer to
Exhaust
Cam wear limit:
: Refer to
PBIC3178J
Standard:
: Refer to
.
PBIC3179J
Standard
: Refer to
.
JPBIA4192ZZ
Standard and Limit
: Refer to
.
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< REMOVAL AND INSTALLATION >
[HR16DE]
CAMSHAFT
2.
Install a dial indicator (A) in thrust direction on front end of cam-
shaft. Measure the camshaft end play on the dial indicator when
camshaft is moved forward/backward (in direction to axis).
• Measure the following parts if out of the standard.
- Dimension “A” for cylinder head No. 1 journal bearing
- Dimension “B” for camshaft thrust
• Refer to the standards above, and then replace camshaft and/
or cylinder head.
Camshaft Sprocket Runout
1.
Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
2.
Measure the camshaft sprocket runout with a dial indicator.
(Total indicator reading)
• If it exceeds the limit, replace camshaft sprocket.
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to
.
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
Standard and Limit
: Refer to
.
PBIC3694E
Standard
: 4.000 - 4.030 mm (0.1574 - 0.1586 in)
Standard
: 3.877 - 3.925 mm (0.1526 - 0.1545 in)
KBIA3345J
Limit
: 0.15 mm (0.0059 in)
JPBIA4193ZZ
KBIA0182E
CAMSHAFT
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• Measure the outer diameter of valve lifter with a micrometer (A).
VALVE LIFTER HOLE DIAMETER
Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer (A).
VALVE LIFTER CLEARANCE
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
• If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diame-
ter, replace either or both valve lifter and cylinder head.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak.
• 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-13, "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.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
• Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including 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:
Standard
: Refer to
.
PBIC3185J
Standard
: Refer to
.
PBIC3184J
Standard
: Refer to
.
Items
Before starting engine
Engine running
After engine stopped
Engine coolant
Level
Leakage
Level
Engine oil
Level
Leakage
Level
Other oils and fluid*
Level
Leakage
Level
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