Juke F15 (2012 year). Service Repair Manual — part 183
EM-76
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[MR16DDT ]
TIMING CHAIN
b.
Secure crankshaft pulley (1) with a pulley holder (commercial
service tool) (A).
c.
Apply new engine oil to thread and seat surfaces of crankshaft
pulley bolt.
d.
Tighten crankshaft pulley bolt.
e.
Put a paint mark (B) on crankshaft pulley (2), matching with any
one of six easy to recognize angle marks (A) on crankshaft pul-
ley bolt (1) flange.
f.
Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark.
g.
Check that crankshaft rotates clockwise smoothly.
13. Install remaining parts in the reverse order of removal.
Inspection
INFOID:0000000006337276
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.
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
PBIC3961E
PBIC3963E
PBIC3169J
TIMING CHAIN
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• 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:
*: Transmission/transaxle/CVT fluid, 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
Other oils and fluid*
Level
Leakage
Level
Fuel
Leakage
Leakage
Leakage
EM-78
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CAMSHAFT
CAMSHAFT
Exploded View
INFOID:0000000006337277
1.
Camshaft position sensor (PHASE)
2.
O-ring
3.
Camshaft bracket
4.
Camshaft (EXH)
5.
Camshaft sprocket (EXH)
6.
Camshaft sprocket (INT)
7.
Camshaft (INT)
8.
Valve lifter (EXH)
9.
Valve lifter (INT)
10. Signal plate (INT)
11
Signal plate (EXH)
A.
Tightening must be done following
the installation procedure.
Refer to
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
: Should be lubricated with oil.
: Sealing point
: Select with proper thickness.
JPBIA4315GB
CAMSHAFT
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Removal and Installation
INFOID:0000000006337278
CAUTION:
The rotating direction in the text indicates all directions seen from the engine front.
REMOVAL
1.
Remove the following parts.
• Intake manifold: Refer to
• Rocker cover: Refer to
• Front cover and timing chain related parts: Refer to
NOTE:
Removal of oil pump drive related part is not necessary.
2.
Remove camshaft position sensor (PHASE) from camshaft bracket.
CAUTION:
• Handle camshaft position sensor (PHASE) carefully and avoid impacts.
• Never disassemble camshaft position sensor (PHASE).
• Never place sensor where it is exposed to magnetism.
3.
Put the matching mark (A) on the camshaft sprocket (INT) (1),
camshaft sprocket (EXH) (2) and the camshaft bracket (1) as
shown in the figure.
NOTE:
It prevents the knock pin of the camshaft (INT) from engaging
with the incorrect pin hole when installing the camshaft sprocket
(INT).
4.
Remove camshaft sprockets (INT and EXH).
• Secure hexagonal part (A) of camshaft with a wrench. Loosen
camshaft sprocket mounting bolts and remove camshaft
sprocket.
CAUTION:
• Never rotate crankshaft or camshaft while timing chain
is removed. It causes interference between valve and
piston.
• Never loosen the mounting bolts with securing anything
other than the camshaft hexagonal part or with tension-
ing the timing chain.
5.
Remove camshaft bracket with the following procedure:
a.
Loosen mounting bolts in reverse order as shown in the figure.
JPBIA4404ZZ
1
: Camshaft sprocket (INT)
2
: Camshaft sprocket (EXH)
JPBIA4405ZZ
: Engine front
JPBIA4406ZZ
EM-80
< UNIT DISASSEMBLY AND ASSEMBLY >
[MR16DDT ]
CAMSHAFT
b.
Cut liquid gasket by prying the position (
) shown in the figure,
and then remove the camshaft bracket.
CAUTION:
• Be careful not to damage the mating surface.
• A more adhesive liquid gasket is applied compared to pre-
vious types when shipped, so it should not be forced off
the position not specified.
6.
Remove camshafts.
7.
Remove valve lifters.
• Identify installation positions, and store them without mixing them up.
8.
Remove signal plate from camshaft, if necessary.
INSTALLATION
1.
Install valve lifters.
• Install them in the original positions.
2.
Install camshafts.
• Clean camshaft journal to remove any foreign material.
• Distinguish between the intake and the exhaust by looking at
the different shapes of the front and rear ends of the camshaft
or using the identification colors (A) and (B).
• Install camshafts so that camshaft dowel pins (A) on the front
side are positioned as shown in the figure.
NOTE:
Though camshaft does not stop at the positions as shown in
the figure, for the placement of cam nose, it is generally
accepted camshaft is placed for the same direction of the fig-
ure.
3.
Install camshaft bracket with the following procedure:
a.
Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face.
: Engine front
JPBIA4407ZZ
1
: Camshaft (EXH)
2
: Camshaft (INT)
Identification color
A
B
Camshaft (EXH)
—
Yellow
Camshaft (INT)
Yellow
—
1
: Camshaft (EXH)
2
: Camshaft (INT)
JPBIA4408ZZ
JPBIA4409ZZ
CAMSHAFT
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b.
Apply liquid gasket (A) to camshaft bracket as shown in the fig-
ure.
Use Genuine Liquid Gasket or equivalent.
c.
Tighten mounting bolts of camshaft brackets in the following
steps, in numerical order as shown in the figure.
• There are two types of mounting bolts. Refer to the following
for locating bolts.
i.
Tighten mounting bolts in numerical order.
ii.
Tighten mounting bolts in numerical order.
iii.
Tighten mounting bolts in numerical order.
CAUTION:
After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket
from the mating surface of cylinder head.
4.
Install the camshaft sprocket (INT) to the camshaft (INT) with the following procedure.
b
: Plug hole inner wall
c
: 3.4 - 4.4mm (0.134 - 0.173 in)
: Engine front
: Engine outside
JPBIA4410ZZ
: Engine front
M6 bolts [thread length: 57.5 mm (2.264 in)]
: 13, 14, and 15 in the figure
M6 bolts [thread length: 35.0 mm (1.378 in)]
: Except the above
: 1.96 N·m (0.20 kg-m, 17 in-lb)
: 5.88 N·m (0.60 kg-m, 52 in-lb)
: 9.5 N·m (0.97 kg-m, 84 in-lb)
JPBIA4406ZZ
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CAMSHAFT
a.
When the camshaft sprocket (INT) (2) and camshaft sprocket
(EXH) (3) is removed, refer to the paint mark (A) put according
to step “3”. Securely align the knock pin and the pin hole, and
then install them.
b.
Tighten bolts in the following steps.
• Secure the hexagonal part of camshaft (INT) using wrench to tighten mounting bolt.
i.
Tighten camshaft (INT) mounting bolt.
ii.
Turn 67 degrees clockwise (angle tightening).
CAUTION:
Check the tightening angle by using an angle wrench [SST:
KV10112100 (BT8653-A)] (B) or protractor. Never judge by
visual inspection without an angle wrench.
5.
Install timing chain and related parts. Refer to
.
6.
Inspect and adjust valve clearance. Refer to
EM-14, "Inspection and Adjustment"
7.
Install remaining parts in the reverse order of removal.
Inspection
INFOID:0000000006337279
INSPECTION AFTER REMOVAL
Camshaft Runout
1.
Put V-block on a precise flat table, and support No. 2 and 5 journal 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 dial indicator (A) vertically to No. 3 journal.
3.
Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
4.
If it exceeds the limit, replace camshaft.
Camshaft Cam Height
1
: Camshaft bracket
JPBIA4404ZZ
: 35.0 N·m (3.6 kg-m, 26 ft-lb)
1
: Camshaft sprocket (INT)
A
: Camshaft (INT) hexagonal part
JPBIA4412ZZ
Standard and Limit
: Refer to
.
PBIC3177J
CAMSHAFT
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1.
Measure the camshaft cam height with a micrometer (A).
2.
If it exceeds the limit, replace camshaft.
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER
Measure the outer diameter of camshaft journal with a micrometer
(A).
CAMSHAFT BRACKET INNER DIAMETER
• Tighten camshaft bracket bolts with specified torque. Refer to
EM-79, "Removal and Installation"
• Measure the inner diameter 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 camshaft or cylinder head, or both.
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
Camshaft End Play
1.
Install camshaft in cylinder head. Refer to
EM-79, "Removal and Installation"
Standard and Limit
: Refer to
.
PBIC3178J
Standard
: Refer to
PBIC3179J
B
: Measuring direction of inner diameter
Standard
: Refer to
PBIC3180J
Standard and Limit
: Refer to
.
EM-84
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CAMSHAFT
2.
Install dial indicator in thrust direction on front end of camshaft.
Read the end play of dial indicator (A) when camshaft is moved
forward/backward (in direction to axis).
• Measure the following parts if out of the standard.
- Dimension (A) for groove of cylinder head No. 1 journal
- Dimension (B) for camshaft flange
• 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 (A).
(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
.
PBIC3181J
Standard
: 4.000 - 4.030 mm (0.1575 - 0.1587 in)
Standard
: 3.877 - 3.925 mm (0.1526 - 0.1545 in)
PBIC3183J
Limit
: Refer to
.
JPBIA4413ZZ
KBIA0182E
CAMSHAFT
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• Measure the outer diameter of valve lifter with a micrometer (A).
VALVE LIFTER HOLE DIAMETER
Measure the inner 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 diameter, replace either or both
valve lifter and cylinder head.
INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III
and it is directed according to inspection procedure of EC section. Refer to
• Check when engine is cold so as to prevent burns by the splashing engine oil.
1.
Check engine oil level. Refer to
.
2.
Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a.
Release the fuel pressure. Refer to
.
b.
Remove intake manifold. Refer to
c.
Disconnect ignition coil and injector harness connectors.
d.
Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket (RH) and engine mounting insulator (RH). Refer to
3.
Remove intake valve timing control solenoid valve. Refer to
• Lift the front side of the engine with a jack base to remove intake valve timing control solenoid valve.
4.
Clean the mounting area of intake valve timing control solenoid valve, and then insert a clean waste with
no oil adhesion into the oil hole of the cylinder head.
5.
Install engine mounting insulator (RH) and engine mounting bracket (RH). (After the removal of intake
valve timing control solenoid valve and insertion of a waste into the oil hole.)
6.
Perform cranking to check that engine oil comes out from the oil hole (mounting hole of intake valve timing
control solenoid valve) of cylinder head.
• Regarding the engine oil check, judge it by the amount of oil adhered to the wasted inserted into the oil
hole.
WARNING:
• Never insert fingers into the oil hole.
• Be careful not to touch rotating parts (drive belt, idler pulleys and crankshaft pulley, etc.).
CAUTION:
Standard
: Refer to
.
PBIC3185J
Standard
: Refer to
.
Standard
: Refer to
.
PBIC3184J
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CAMSHAFT
• Never perform cranking without installing the engine mounting insulator (RH) and engine mount-
ing bracket (RH).
• Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil
and so as to prevent engine oil contamination.
• Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belt,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
7.
Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
• Remove oil filter (for intake valve timing control), and then clean it. Refer to
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to
LU-3, "Engine Lubrication System Schematic"
8.
Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to
LU-3, "Engine Lubrication System"
.
9.
After inspection, install removed parts in the reverse order.
OIL SEAL
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OIL SEAL
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation
INFOID:0000000006337280
REMOVAL
1.
Remove camshafts. Refer to
.
2.
Remove valve lifters. Refer to
3.
Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
4.
Remove valve collet.
• Compress valve spring with the valve spring compressor [SST:
KV10116200 (J-26336-A)] (A), the attachment [SST:
KV10115900 (J-26336-20)] (C), and the adapter [SST:
KV10109220 (
—
)] (B). Remove valve collet with magnet
hand.
CAUTION:
Be careful not to damage valve lifter holes.
5.
Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
Never remove valve spring seat from valve spring.
6.
Remove valve oil seal with the valve oil seal puller [SST:
KV10107902 (J-38959)] (A).
INSTALLATION
1.
Apply new engine oil to valve oil seal joint surface and seal lip.
2.
Press in valve oil seal to the height (H) shown in the figure with
the valve oil seal drift [SST: KV10115600 (J-38958)] (A).
3.
Install in the reverse order of removal, for the rest of parts.
FRONT OIL SEAL
JPBIA1365ZZ
PBIC3210J
Height (H)
: 15.1 - 15.7 mm (0.594 - 0.618 in)
PBIC3211J
EM-88
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[MR16DDT ]
OIL SEAL
FRONT OIL SEAL : Removal and Installation
INFOID:0000000006337281
REMOVAL
1.
Remove the following parts.
• Front fender protector (RH): Refer to
• Drive belt: Refer to
• Crankshaft pulley: Refer to
.
2.
Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.
INSTALLATION
1.
Apply new engine oil to new front oil seal joint surface and seal lip.
2.
Install front oil seal so that each seal lip is oriented as shown in
the figure.
• Press-fit front oil seal using a suitable drift with outer diameter 57 mm (2.24 in) and inner diameter 45
mm (1.77 in).
CAUTION:
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilting.
3.
Install in the reverse order of removal, for the rest of parts.
REAR OIL SEAL
REAR OIL SEAL : Removal and Installation
INFOID:0000000006337282
REMOVAL
1.
Remove transaxle assembly. Refer to
(M/T models).
2.
Remove clutch cover and clutch disk (M/T models). Refer to
CL-29, "EXCEPT FOR K9K : Exploded
.
3.
Remove drive plate (CVT models) or flywheel (M/T models). Refer to
.
4.
Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1.
Apply the liquid gasket lightly to entire outside area of new rear oil seal.
Use Genuine Liquid Gasket or equivalent.
A
: Dust seal lip
B
: Oil seal lip
: Engine outside
: Engine inside
PBIC3485J
Within 0.3 mm (0.012 in) toward engine front (crankshaft pulley side)
Within 0.5 mm (0.020 in) toward engine rear (crankshaft sprocket side)
OIL SEAL
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2.
Install rear oil seal so that each seal lip is oriented as shown in
the figure.
• Press-fit rear oil seal with a suitable drift (A) outer diameter
115 mm (4.53 in) and inner diameter 90 mm (3.54 in).
CAUTION:
• Be careful not to damage crankshaft and cylinder block.
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
• Never touch grease applied onto oil seal lip.
• Press in rear oil seal (1) to the position as shown in the figure.
3.
Install in the reverse order of removal, for the rest of parts.
A
: Dust seal lip
B
: Oil seal lip
: Engine outside
: Engine inside
PBIC3485J
JPBIA4414ZZ
A
: Rear end surface of cylinder block
PBIC3952E
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CYLINDER HEAD
CYLINDER HEAD
Exploded View
INFOID:0000000006337283
REMOVAL
DISASSEMBLY
1.
Cylinder head assembly
2.
Cylinder head bolt
3.
Cylinder head gasket
A.
Tightening must be done following
the installation procedure.
Refer to
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
: Should be lubricated with oil.
JPBIA4316ZZ
CYLINDER HEAD
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Removal and Installation
INFOID:0000000006337284
REMOVAL
1.
Remove the following components and related parts.
• Exhaust manifold: Refer to
• Intake manifold: Refer to
• Fuel injector and fuel tube assembly: Refer to
• Water outlet: Refer to
.
• Rocker cover: Refer to
• Front cover, timing chain: Refer to
.
• Camshaft: Refer to
.
2.
Remove cylinder head.
1.
Valve collet
2.
Valve spring retainer
3.
Valve spring (EXH)
4.
valve spring seat
5.
Valve oil seal
6.
Valve guide (EXH)
7.
Valve seat (EXH)
8.
Valve (EXH)
9.
Valve (INT)
10. Valve seat (INT)
11. Cylinder head
12. Valve guide (INT)
13. Spark plug
14. Valve spring (INT)
A.
Replacement must be following the
disassembly and assembly proce-
dure.
Refer to
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
: Should be lubricated with oil.
JPBIA4317GB
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