Juke F15 (2012 year). Service Repair Manual — part 195

EM-268

< PREPARATION >

[K9K]

PREPARATION

KV113B0150
(Mot. 1492-03)
Bearing assembling adapter

Adaptation kit for installing the detachable cap
connecting rod bearing

KV113B0160
(Mot. 1493-01)
Bearing insert

Tool for installing main bearing

KV113B0170
(Mot. 1494)
Oil jet remover plate

Tool for removing oil jets

KV113B0190
(Mot. 1567)
Clip pliers

Pliers for exhaust gas recycling pipe clips

KV113B0210
(Mot. 1585)
Front oil seal drift

Tool for installing crankshaft seals, flywheel
end

KV113B0220
(Mot. 1586)
Front oil seal drift set

Tool for installing crankshaft seals, timing end

KV113B0230
(Mot. 1632)
Camshaft seal insert

Tool for installing inlet camshaft seals

KV113B0240
(Rou. 15-01)
Shaft protector

Internal shaft protector
16 mm (0.63 in) dia.

EM03470000
(

—

)

Piston ring compressor

Installing piston assembly into cylinder bore

KV10111100
(

—

)

Seal cutter

Removing oil pan

NISSAN tool number
(RENAULT tool No.)
Tool name

Description

MBIB0375E

MBIB0376E

MBIB0381E

NT044

NT046

PREPARATION

EM-269

< PREPARATION >

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Commercial Service Tool

INFOID:0000000006449964

KV10112100
(

—

)

Angle wrench

Tightening bolts for bearing cap, cylinder
head, etc. in angle

—
(Mot. 1638)
Belt tension gauge

Setting drive belt tension

—
(Mot. 1606-A)
Camshaft pulley holder

Tool for locking sprockets for toothed timing
belt

NISSAN tool number
(RENAULT tool No.)
Tool name

Description

NT014

MBIB0382E

MBIB1922E

NISSAN tool number
(RENAULT tool No.)
Tool name

Description

KV113B0030
(Mot. 11)
Crankshaft bearing remover

Crankshaft bearing extractor

KV113B0040
(Mot. 251-01)
Dial gauge stand set

Gauge stand used with KV113B0050 (Mot.
252-01)

KV113B0050
(Mot. 252-01)
Dial gauge stand set

Thrust plate for measuring the protrusion of
cylinder liners used with KV113B0040 (Mot.
251-01).

MBIB0359E

MBIB0360E

MBIB0361E

EM-270

< PREPARATION >

[K9K]

PREPARATION

KV113B0090
(Mot. 1335)
Valve seal remover

Tool for removing valve stem seals

KV113B0180
(Mot. 1511-01)
Valve seal drift

Tool for installing valve stem seals

KV113B0200
(Mot. 1573)
Cylinder head stand

Cylinder head support

KV113E0010
(Mot. 1566)
Fuel spill tube spanner

Spanner for installing and removing high pres-
sure pipes

WS39930000
(

—

)

Tube presser

Pressing the tube of liquid gasket

Manual lift table caddy

Removing and installing engine

Piston ring expander

Removing and installing piston ring

NISSAN tool number
(RENAULT tool No.)
Tool name

Description

MBIB0370E

MBIB0378E

MBIB0380E

MBIB0379E

NT052

ZZA1210D

NT030

PREPARATION

EM-271

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(Mot. 588)

Liner retaining strap

(664000)
Cylinder head test container

Tool for testing the cylinder head, including: a
tray and the various kits suited for each model
of cylinder head (plug, sealing plate, blanking
plate).

Torx socket

Standard 1/2" (12.7 mm) square drive 8/12 /14
female torx socket.

(Mot. 1505)
(Mot. 1715)
Frequency meter

Tool for belt tension checking with frequency

Glow plug wrench

Articulated wrench for removing and installing
the glow plugs

Main bearing wrench

Wrench for removing main bearings

NISSAN tool number
(RENAULT tool No.)
Tool name

Description

MBIB0364E

MBIB0383E

MBIB1423E

MBIB0387E

MBIB0388E

EM-272

< BASIC INSPECTION >

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CAMSHAFT VALVE CLEARANCE

BASIC INSPECTION

CAMSHAFT VALVE CLEARANCE

Valve Clearance

INFOID:0000000006449965

CHECKING AND ADJUSTING THE VALVE CLEARANCE

1.

Install the tappet.

2.

Install the camshaft.

3.

Install the camshaft brackets.

4.

Place the valves of the cylinder concerned at the “end of
exhaust - beginning of inlet” position and check the clearance
(X).
NOTE:
Dimension (Y) corresponds to the tappet thickness sizes (there
are 25 sizes at the service parts).

5.

Compare the values recorded with the values specified, then replace the tappets which are not within tol-
erance.

6.

Remove the camshaft brackets.

7.

Remove the camshaft.

8.

Remove the tappet not within tolerance.
Determining dimension Y.
Set up the following assembly using KV113B0050 (Mot. 252-01)
(Commercial service tool) or equivalent tool and dial gauge,
then calibrate the gauge.

9.

Raise the gauge extension (without modifying the position of the
magnetic support/gauge assembly), then slide in the tappet to
be measured.
• Note dimension (Y) and repeat the operation for the tappets

where the valve clearance is not within tolerance.

• Refer to the Replacement Parts Catalogue for the vehicle con-

cerned to select the various thicknesses of the tappet(s).

10. Check the valve clearance again.

11. Remove the camshaft brackets.
12. Remove the camshaft.

13. Remove the tappet(s) not within tolerance.

: 11 N·m (1.1 kg-m, 8 ft-lb)

1
3
4
2

4
2
1
3

Clearance, when the engine cold:

Intake

: 0.125 - 0.25 mm (0.0049 - 0.0098 in)

Exhaust

: 0.325 - 0.45 mm (0.0128 - 0.0177 in)

MBIB0333E

MBIB0334E

MBIB0335E

CAMSHAFT VALVE CLEARANCE

EM-273

< BASIC INSPECTION >

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14. Grease the underside of the tappets and the camshaft brackets.

15. Degrease the gasket faces (of the cylinder head and brackets 1

and 6). They should be clean, dry and free from grease (in par-
ticular, remove finger marks).

16. Lay four beads of Loctite with a width of 1 mm (0.04 in) on

brackets 1 and 6 of the cylinder head.

17. Install the camshaft.

18. Install the camshaft brackets (these are numbered from 1 to 6

and bearing (1) should be positioned on the flywheel end).

: 11 N·m (1.1 kg-m, 8 ft-lb)

MBIB0427E

EM-274

< SYMPTOM DIAGNOSIS >

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NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

SYMPTOM DIAGNOSIS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting - Engine Noise

INFOID:0000000006449966

MBIB0554E

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

EM-275

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Use the Chart Below to Help You Find the Cause of the Symptom

INFOID:0000000006449967

1.

Locate the area where noise occurs.

2.

Confirm the type of noise.

3.

Specify the operating condition of engine.

4.

Check specified noise source.

If necessary, repair or replace these parts.

A: Closely related

B: Related

C: Sometimes related

—: Not related

Location

of noise

Type of

noise

Operating condition of engine

Source of

noise

Check item

Refer-

ence page

Before

warm-

up

After

warm-

up

When

start-

ing

When

idling

When

racing

While

driving

Top of en-
gine
Rocker
cover
Cylinder
head

Ticking or
clicking

C

A

—

A

B

—

Tappet
noise

Valve clearance

EM-272

Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil pan

Slap or
rap

A

—

—

B

B

A

Piston
slap noise

Piston ring end gap

EM-353

Front of
engine
Timing
belt cover

Tapping or
ticking

A

A

—

B

B

B

Timing
belt ten-
sioner
noise

Timing belt tensioner
operation

EM-302

Front of
engine

Squeak-
ing or fizz-
ing

A

B

—

B

—

C

Drive belts
(Sticking
or slip-
ping)

Drive belts deflection

EM-276

Squall
Creak

A

B

—

B

A

B

Water
pump
noise

Water pump operation

CO-70

EM-276

< PERIODIC MAINTENANCE >

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DRIVE BELT

PERIODIC MAINTENANCE

DRIVE BELT

Checking Drive Belts

INFOID:0000000006449968

WARNING:

Be sure to perform when the engine is stopped.

1.

Inspect belts for cracks, fraying, wear and oil. If necessary,
replace.

2.

Evaluate manually if the belt is enough tensioned (tension can-
not be measured by way of frequency meter).

CAUTION:

Auto-tensioner must be replaced with a new one when the
belt is replaced.

Tension Adjustment

INFOID:0000000006449969

Belt tensioning is not necessary, as it is automatically adjusted by auto-tensioner.

Removal and Installation

INFOID:0000000006449970

CAUTION:

• Replace any belt that has been removed with a new one.
• Auto-tensioner must be replaced with new ones when the belt is replaced.
• Never run the engine without the drive belts to avoid damaging the crankshaft pulley.

REMOVAL

1.

Remove engine undercover.

2.

Remove RH front wheel.

3.

Remove fender protector RH. Refer to

EXT-22, "Exploded View"

.

4.

Remove drive belt.

• Turn clockwise adjusting bolt.

5.

If necessary, remove auto-tensioner.

INSTALLATION

1.

Install auto-tensioner mounting bolt.

MBIB0664E

MBIB0353E

Auto-tensioner mounting bolt

: 40 N·m (4.1 kg-m, 30 ft-lb)

DRIVE BELT

EM-277

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• Align the notch and tighten mounting bolt.

2.

Install the drive belt.

CAUTION:

• Make sure belt is correctly engaged with the pulley

groove.

• Check for oil and coolant on belt and each pulley groove.
• Certain drive belts have five teeth whereas the air condi-

tioning compressor pulley, power-assisted steering pump
pulley, and alternator pulley all have six teeth.In this case,
it is essential to check that inner tooth (O) of the pulleys
remains free when fitting the drive belt.
Never turn the engine in the opposite direction to its nor-
mal operating direction.
Use a brush to remove any deposits from the crankshaft
pulley V grooves.
For engines fitted with a mechanical tensioning roller, it is essential to replace the tensioning
roller mounting bolts.

3.

Make sure that tension of each belt is within the standard.

MBIB0558E

MBIB0516E

EM-278

< PERIODIC MAINTENANCE >

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AIR CLEANER FILTER

AIR CLEANER FILTER

Exploded View

INFOID:0000000006449971

Removal and Installation

INFOID:0000000006449972

REMOVAL

1.

Push the tabs (A) of both ends of the air cleaner cover (1) into
the inside (B).

2.

Pull up the air cleaner cover forward (C) and remove it.

JPBIA4801GB

1.

Turbocharger air inlet pipe

2.

Clamp

3.

Air duct (suction)

4.

Air mass flow sensor

5.

O-ring

6.

Air duct (inlet)

7.

Grommet

8.

Air cleaner case

9.

Air cleaner filter

10. Cover

11.

Holder

A.

: To turbocharger

: Vehicle front

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA3074ZZ

AIR CLEANER FILTER

EM-279

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3.

Remove the air cleaner filter (1) and holder (2) assembly from
the air cleaner case.

4.

Remove the air cleaner filter from the holder.

INSTALLATION

Install in the reverse order of removal.

JPBIA3075ZZ

EM-280

< REMOVAL AND INSTALLATION >

[K9K]

AIR CLEANER AND AIR DUCT

REMOVAL AND INSTALLATION

AIR CLEANER AND AIR DUCT

Exploded View

INFOID:0000000006449973

Removal and Installation

INFOID:0000000006449974

REMOVAL

1.

Remove resonator.

2.

Remove air duct (inlet).

3.

Remove battery. Refer to

PG-124, "Exploded View"

.

4.

Remove air duct (suction).

5.

Disconnect mass air flow sensor harness connector.

6.

Remove air cleaner case by sliding the air cleaner case frontward.

CAUTION:

Slide the air cleaner case carefully so as not to damage it on the air cleaner case and harness
bracket.

INSTALLATION

• Install in the reverse order of removal.

JPBIA4801GB

1.

Turbocharger air inlet pipe

2.

Clamp

3.

Air duct (suction)

4.

Air mass flow sensor

5.

O-ring

6.

Air duct (inlet)

7.

Grommet

8.

Air cleaner case

9.

Air cleaner filter

10. Cover

11.

Holder

A.

: To turbocharger

: Vehicle front

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

CHARGE AIR COOLER

EM-281

< REMOVAL AND INSTALLATION >

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CHARGE AIR COOLER

Exploded View

INFOID:0000000006449975

Removal and Installation

INFOID:0000000006449976

REMOVAL

1.

Remove front bumper. Refer to

EXT-12, "Exploded View"

.

2.

Remove air guide (RH).

3.

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

1.

Air inlet hose

2.

Clamp

3.

Air inlet tube

4.

Air inlet hose

5.

Charge air cooler

6.

Air inlet hose

7.

Air inlet tube

8.

Turbocharger

9.

Air inlet tube assembly

A.

1st step: 5.0 N·m (0.51 kg-m, 44 ft-lb)
2nd step: 7.0 N·m (0.71 kg-m, 62 ft-
lb)

B.

Paint mark

C.

To electric throttle control actuator

: Vehicle front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

JPBIA3030GB

EM-282

< REMOVAL AND INSTALLATION >

[K9K]

CHARGE AIR COOLER

4.

Remove charge air cooler (1).

CAUTION:

• Avoid interference between the charge air cooler and radiator.
• When removing charge air cooler, close opening on turbo

charger and intake manifold with shop cloth or other suitable
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-281, "Removal and Installation"

.

Inspection

INFOID:0000000006449977

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-59, "Inspection"

.

JPBIA3091ZZ

EGR VALVE

EM-283

< REMOVAL AND INSTALLATION >

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EGR VALVE

Exploded View

INFOID:0000000006449978

Removal and Installation

INFOID:0000000006449979

REMOVAL

1.

Drain engine coolant. Refer to

CO-62, "Draining"

.

2.

Remove air cleaner case. Refer to

EM-280, "Exploded View"

.

3.

Remove cowl top extension. Refer to

EXT-20, "Exploded View"

.

4.

Remove turbocharger air inlet pipe. Refer to

EM-280, "Exploded View"

.

5.

Remove air inlet tube assembly and air inlet tube. Refer to

EM-281, "Exploded View"

.

6.

Remove electric throttle control actuator.

7.

Disconnect EGR solenoid valve connector.

8.

Remove cooling hose.

9.

Remove EGR volume control valve housing mounting bolts.

10. Remove EGR assembly.

INSTALLATION

• Install in the reverse order of removal.

1.

EGR valve assembly

2.

Clamp

3.

EGR tube

4.

Air inlet tube

5.

O-ring

6.

Gasket

7.

EGR cooler

8.

Gasket

9.

EGR volume control valve housing

10. Gasket

11.

Electric throttle control actuator

12. Gasket

13. EGR volume control valve

14. Clamp

15. Cooling hose

A.

To exhaust manifold

B.

To intake manifold

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

JPBIA3037GB