Juke F15 (2012 year). Service Repair Manual — part 197

EM-300

< REMOVAL AND INSTALLATION >

[K9K]

ROCKER COVER

ROCKER COVER

Exploded View

INFOID:0000000006450000

Removal and Installation

INFOID:0000000006450001

REMOVAL

1.

Remove air cleaner case. Refer to

EM-280, "Exploded View"

.

2.

Remove inlet pipe assembly and air inlet tube. Refer to

EM-281, "Exploded View"

.

3.

Remove high pressure protection cover (upper). Refer to

EM-294, "Exploded View"

.

4.

Remove electric throttle control actuator.

5.

Remove fuel injector. Refer to

EM-294, "Exploded View"

.

6.

Remove rocker cover.
• Loosen holding bolts in the reverse order as shown in the fig-

ure and remove.

INSTALLATION

JPBIA3109GB

1.

Blow-by hose

2.

Rocker cover

3.

Gasket

4.

Camshaft position sensor

5.

O-ring

A.

To turbocharger air inlet pipe

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

: Engine front

JPBIA3119ZZ

ROCKER COVER

EM-301

< REMOVAL AND INSTALLATION >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

1.

Apply liquid gasket on locations shown in the figure.
• Use Genuine Liquid gasket or equivalent.

2.

Tighten holding bolts in the numerical order as shown in the fig-
ure.

3.

Install in the reverse order of removal after this steps.

MBIB0581E

: Engine front

: 12 N·m (1.2 kg-m, 9 ft-lb)

JPBIA3119ZZ

EM-302

< REMOVAL AND INSTALLATION >

[K9K]

TIMING BELT

TIMING BELT

Exploded View

INFOID:0000000006450002

Removal and Installation

INFOID:0000000006450003

CAUTION:

• Apply new engine oil to parts marked in illustration before installation.
• Replace any belt that has been removed.
• Never turn the engine in the direction opposite to that of normal operation.
• When replacing the timing belt, be sure to replace the timing belt tensioner.
• Never run the engine without the drive belts to avoid damaging the crankshaft pulley.

REMOVAL

1.

Disconnect battery cable from the negative terminal.

2.

Remove engine under cover.

3.

Remove front wheel RH.

4.

Remove fender protector RH. Refer to

EXT-22, "Exploded View"

5.

Remove drive belt, and auto-tensioner. Refer to

EM-276, "Removal and Installation"

.

6.

Remove RH engine torque rod.

JPBIA3140GB

1.

Timing belt inner cover

2.

Timing belt

3.

Camshaft sprocket

4.

Timing belt tensioner

5.

Timing belt upper cover

6.

Timing belt lower cover

7.

Cylinder head suspended bracket

8.

Crankshaft pulley

9.

Crankshaft sprocket

10. Rear oil seal

11.

Rear oil seal retainer

12. Gasket

A

Refer to

EM-311

B

Refer to

EM-302

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

: Should be lubricated with oil.

TIMING BELT

EM-303

< REMOVAL AND INSTALLATION >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

7.

Remove RH engine mounting.

8.

Remove RH engine mounting support bracket and RH engine mounting insulator.

9.

Remove upper timing cover, camshaft position sensor and cylin-
der head suspended mounting bracket.

10. Remove timing belt lower cover.

11. Remove the TDC pin bolt.

12. Rotate the crankshaft clockwise, until the position (A) of the

camshaft pulley becomes opposite of the position (B) on the cyl-
inder head.

MBIB1041E

MLIA0003E

MBIB0392E

MBIB1923E

EM-304

< REMOVAL AND INSTALLATION >

[K9K]

TIMING BELT

13. Insert TDC set pin [SST: KV113B0110 (Mot. 1430)] (A) into the

camshaft pulley and cylinder head hole.

14. Screw in the TDC pin (special service tool).

15. Turn the engine clockwise (timing side) until the crankshaft

reaches the TDC pin (special service tool).

16. The pin [SST: KV113B0110 (Mot. 1430)] (A) must engage in the

camshaft pulley and cylinder head holes.

17. Insert flat-bladed screwdriver into the place of crankshaft posi-

tion sensor to block crankshaft and loosen crankshaft pulley bolt
(1).

18. Remove crankshaft pulley.

CAUTION:

Never remove fixing bolts. Keep loosened fixing bolts in
place to protect removed crankshaft pulley from dropping.

MBIB1924E

MBIB0394E

MBIB0395E

MBIB1924E

MBIB1925E

TIMING BELT

EM-305

< REMOVAL AND INSTALLATION >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

19. Slacken the timing belt by loosening the bolt of tensioner (1),

then remove timing belt.

INSTALLATION

Install in the reverse order of removal paying attention to the following.

TIMING ADJUSTMENT

CAUTION:

It is essential to degrease the end of the crankshaft, the bore of the crankshaft sprocket and the bear-
ing faces of the drive belt pulley to prevent any slip between the timing and the crankshaft which
would risk destroying the engine.
1.

Install timing belt tensioner.
NOTE:
Put the timing belt tensioner spigot (1) in the cylinder head
groove.

2.

Insert Tool KV113B0110 (Mot. 1430) (A) in the camshaft pulley
and cylinder head holes.

3.

Check that the mark on the high pressure pump pulley (2) has
shifted one tooth to the right of vertical axle.

4.

Turn crankshaft to set Tool KV113B0130 (Mot. 1489) (the crank-
shaft groove (1) must be facing upwards).

5.

Tighten old crankshaft pulley bolt with a spacer (1) (which does
not cover the timing sprocket mark).

MBIB1926E

MBIB1927E

MBIB1928E

MBIB1929E

EM-306

< REMOVAL AND INSTALLATION >

[K9K]

TIMING BELT

6.

Insert tool KV113B0130 (Mot. 1489) to crankshaft.

7.

Remove one wheel bolt from crankshaft pulley, and then loosen
the other two bolts (1).

8.

Install the timing belt, aligning the marks on the belt with those on the camshaft and fuel injection pump
sprockets (19 teeth spaces on the belt between the marks on the camshaft and pump sprockets).

9.

Using a 6 mm (0.24 in) Allen key, move the movable index (F) of
the tension wheel into the position shown below, by turning the
key counterclockwise.

10. Tighten the tension wheel bolt.

11. Check that the camshaft pulley wheel bolts are not fully up against the camshaft pulley wheel.
12. Install and tighten camshaft pulley wheel bolt.

13. Remove Tool KV113B0130 (Mot. 1489) and Tool KV113B0110 (Mot. 1430).

MBIB0395E

MBIB1930E

MBIB0509E

: 27 N·m (2.8 kg-m, 20 ft-lb)

: 14 N·m (1.4 kg-m, 10 ft-lb)

TIMING BELT

EM-307

< REMOVAL AND INSTALLATION >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

14. Turn the crankshaft two full turns in a clockwise direction (timing

side). Just before the hole (A) of the camshaft pulley is opposite
the cylinder head hole (B), insert tool KV113B0130 (Mot. 1489)
into the cylinder block.

15. Then turn the crankshaft slowly and smoothly against TDC set

pin.

16. Insert TDC set pin [SST: KV113B0110 (Mot. 1430)] (A).

If the pin cannot be inserted, perform the following.

a.

Remove TDC set pin [SST: KV113B0130 (Mot. 1489)].

b.

Loosen camshaft pulley wheel bolts.

c.

Turn camshaft pulley to adjust.

d.

Confirm that the crankshaft sprocket groove is facing upward.

e.

Loosen timing belt tensioner bolt.

f.

Move the movable index of the drive belt tensioner into the posi-
tion as shown in the figure, by turning the key clockwise.

g.

Tighten timing belt tensioner bolt.

h.

Install and tighten camshaft sprocket wheel bolts.

i.

Turn the crankshaft two revolutions in a clockwise direction (tim-
ing side). Just before the hole (A) of the camshaft pulley is oppo-
site the cylinder head hole (B), insert TDC set pin [SST:
KV113B0130 (Mot. 1489)] into the cylinder block.

j.

Then turn the crankshaft slowly and smoothly against TDC set
pin.

17. Install crankshaft pulley (1), and tighten the bolts as follows:

a.

Tighten the bolt.

b.

Turn the bolt 95 degrees

±

15 degrees clockwise (angle tighten-

ing).

MBIB1923E

MBIB1924E

: 27 N·m (2.8 kg-m, 20 ft-lb)

: 14 N·m (1.4 kg-m, 10 ft-lb)

MBIB0511E

MBIB1923E

: 120 N·m (12 kg-m, 89 ft-lb)

MBIB1925E

EM-308

< REMOVAL AND INSTALLATION >

[K9K]

TIMING BELT

18. Remove TDC set pin [SST: KV113B0130 (Mot. 1489)] and TDC set pin [SST: KV113B0110 (Mot. 1430)].

19. Apply liquid gasket to the thread of TDC pin plug.

20. Install TDC pin plug.

21. Install the cylinder head suspended bracket.

22. Install the lower timing cover by positioning the tab (M) into the

hole (N) on the inner timing cover.

: 20 N·m (2.0 kg-m, 15 ft-lb)

: 21 N·m (2.1 kg-m, 15 ft-lb)

MBIB0512E

MBIB0513E

TIMING BELT

EM-309

< REMOVAL AND INSTALLATION >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

23. Install the upper timing cover.

24. Install the water pipe.

25. Install the two water hoses.

26. Install the alternator bracket.

MBIB0514E

MBIB0515E

: 22 N·m (2.2 kg-m, 16 ft-lb)

MBIB0356E

: 44 N·m (4.5 kg-m, 32 ft-lb)

MBIB0355E

EM-310

< REMOVAL AND INSTALLATION >

[K9K]

TIMING BELT

27. Install the alternator.

28. Install the A/C compressor.

29. Install the power steering pump or the washer which replaces

the pulley (if the engine has one).

30. 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 the inner tooth (O) of the pul-
leys 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.

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

Engine number

Tightening torque

< D051474

: 21 N·m (2.1 kg-m, 15 ft-lb)

>

≥≥

: 25 N·m (2.6 kg-m, 18 ft-lb)

: 21 N·m (2.1 kg-m, 15 ft-lb)

: 21 N·m (2.1 kg-m, 15 ft-lb)

MBIB0354E

MBIB0516E

CYLINDER HEAD

EM-311

< REMOVAL AND INSTALLATION >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

CYLINDER HEAD

Exploded View

INFOID:0000000006450004

CAUTION:

Apply new engine oil to parts marked in illustration before installation.

Removal and Installation

INFOID:0000000006450005

REMOVAL

1.

Remove the following parts.
• Battery ground cable
• Engine undercover
• RH front wheel

2.

Remove fender protector RH.

3.

Drain engine coolant. Refer to

CO-62, "Draining"

.

CAUTION:

1.

Camshaft sprocket

2.

Cylinder head suspended bracket

3.

Valve lifter

4.

Valve rotator

5.

Valve spring retainer

6.

Valve spring

7.

Exhaust valve

8.

Intake valve

9.

Valve collet

10. Cap

11.

Rear engine slinger

12. Cylinder head gasket

13. Cylinder head

14. Camshaft

15. Front engine slinger

16. Camshaft bracket

17. Oil seal

A

: Refer to

EM-311

.

B

: Refer to

EM-311

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

: Should be lubricated with oil.

: Select with proper thickness.

JPBIA3118GB

EM-312

< REMOVAL AND INSTALLATION >

[K9K]

CYLINDER HEAD

Perform when engine is cold.

4.

Remove air cleaner case. Refer to

EM-280, "Exploded View"

.

5.

Remove radiator upper hose. Refer to

CO-66, "Exploded View"

.

6.

Disconnect fuel feed tube and return tube from high pressure supply pump. Refer to

EM-298, "Exploded

View"

.

7.

Remove oil level gauge guide.

8.

Remove harnesses and connectors.

9.

Remove heater hoses.

10. Remove turbocharger assembly. Refer to

EM-284, "Exploded View"

.

11. Remove drive belt. Refer to

EM-276, "Removal and Installation"

.

12. Remove rocker cover. Refer to

EM-300, "Exploded View"

.

13. Support underneath of engine by setting a manual lift table caddy (commercial service tool) or equivalent

tool.

CAUTION:

Put a piece of wood or something similar as supporting surface, secure a completely stable condi-
tion.

14. Remove timing belt. Refer to

EM-302, "Exploded View"

.

15. Remove engine support bar.

CAUTION:

During the removal operation, always be careful to prevent engine moves downward from the
vehicle.

16. Remove cylinder head bolt in the reverse order as shown.

17. Remove cylinder head assembly.

18. Place the cylinder head on Tool KV113B0200 (Mot. 1573) (Com-

mercial service tool) or equivalent tool.

CAUTION:

Pay strict attention to the rules regarding cleanliness. Refer
to

EM-263, "Precaution for Diesel Equipment"

.

19. Remove high pressure supply pump and related parts. Refer to

EM-294, "Exploded View"

,

EM-298,

"Exploded View"

.

MBIB0323E

MBIB0406E

CYLINDER HEAD

EM-313

< REMOVAL AND INSTALLATION >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

20. Remove the injectors (by marking them in relation to their cylin-

der), glow plugs using Tool KV113E0010 (Mot. 1566) (Commer-
cial service tool) or equivalent tool, and rear engine slinger.

21. Remove the vacuum pump and water outlet.

22. Remove the air inlet pipe (1), front engine slinger (2), EGR unit

(4), and exhaust manifold (3).

23. Remove the camshaft pulley using sprocket holder [SST: —

(Mot. 1606-A)] (A).

24. Remove the camshaft brackets.

MBIB0410E

MBIB0411E

JPBIA3136ZZ

MBIB1931E

MBIB0414E

EM-314

< REMOVAL AND INSTALLATION >

[K9K]

CYLINDER HEAD

25. Remove the tappets, noting their position.

26. Compress the valve springs using the valve lifter.

Remove the keys, upper cups and springs.

NOTE:
Before removing the valves and the valve stem seals, it is
vital to measure position “H” of one of the old seals in rela-
tion to the cylinder head using Tool KV113B0180 (Mot. 1511-
01) (Commercial service tool) or equivalent tool.

27. Install the push rod (A) of Tool KV113B0180 (Mot. 1511-01)

(Commercial service tool) or equivalent tool on the valve stem
seal.
NOTE:
The inner diameter of the push rod must be identical to that
of the valve. In addition, the bottom of the push rod must
come into contact with the metal upper section of the valve
stem seal.

MBIB0415E

MBIB0416E

MBIB0417E

MBIB0418E

CYLINDER HEAD

EM-315

< REMOVAL AND INSTALLATION >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

28. Install the guide tube (B) over the push rod until the guide tube

comes into contact with the cylinder head, locking the push rod
with the knurled wheel.

29. Remove the guide tube assembly plus push rod, being careful

not to loosen the knurled wheel.

30. Remove the valves and valve guide seals using the Tool

KV113B0090 (Mot. 1335) (Commercial service tool) or equiva-
lent tool.

ASSEMBLY OF THE CYLINDER HEAD

1.

Install new valves and grind them gently into their respective
seats. Clean all the parts thoroughly, mark them for identification
purposes, then carry out the refitting operation.
Lubricate the inside of the valve guide.
• It is imperative to fit the valve stem seals using Tool

KV113B0180 (Mot. 1511-01) (Commercial service tool) or
equivalent tool.

NOTE:
Never lubricate the valve stem seals before fitting them.

New Valve Stem Seals

1.

Place the valve in the cylinder head.

2.

Place the barrel of Tool KV113B0180 (Mot. 1511-01) (Commer-
cial service tool) or equivalent tool over the valve stem (the inner
diameter of the barrel must be identical to the diameter of the
valve stem).

3.

Keep the valve pressed against its seat.

4.

Place the valve stem seal (not lubricated) over the tool barrel.

MBIB0419E

MBIB0421E

MBIB0422E

MBIB0423E