Juke F15 (2012 year). Service Repair Manual — part 196

EM-284

< REMOVAL AND INSTALLATION >

[K9K]

TURBOCHARGER

TURBOCHARGER

Exploded View

INFOID:0000000006449980

Removal and Installation

INFOID:0000000006449981

REMOVAL

1.

Remove air cleaner case. Refer to

EM-280, "Exploded View"

.

2.

Remove cowl top extension. Refer to

EXT-20, "Exploded View"

.

3.

Drain engine coolant. Refer to

CO-62, "Draining"

.

4.

Remove diesel particular filter assembly. Refer to

EX-17, "Exploded View"

.

5.

Remove EGR volume control valve housing. Refer to

EM-283, "Exploded View"

.

6.

Remove EGR cooler.

1.

Exhaust manifold

2.

Turbocharger

3.

Gasket

4.

Turbocharger outlet duct

5.

Oil outlet hose

6.

Clamp

7.

Oil return pipe

8.

Gasket

9.

Washer

10. Oil supply tube

11.

O-ring

A.

To EGR tube

B.

To air inlet pipe

C.

To turbocharge air inlet pipe

D.

To diesel particular filter assembly

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

: Should be lubricated with oil.

JPBIA3038GB

TURBOCHARGER

EM-285

< REMOVAL AND INSTALLATION >

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7.

Disconnect 5th injector quick connector and harness connector.

8.

Remove oil tubes.

9.

Remove turbocharger outlet duct bracket.

10. Remove turbocharger assembly (1) as follows:

NOTE:
After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts (A) to remove.

a.

Remove turbocharger oil outlet hose.

CAUTION:

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

11. Remove turbocharger outlet duct.

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:0000000006449982

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.

JPBIA3110ZZ

MBIB1419E

Suction side

: Between turbocharger and air cleaner

Exhaust side

: Between turbocharger and outlet duct

EM-286

< REMOVAL AND INSTALLATION >

[K9K]

EXHAUST MANIFOLD

EXHAUST MANIFOLD

Exploded View

INFOID:0000000006449983

Removal and Installation

INFOID:0000000006449984

REMOVAL

1.

Remove turbocharger assembly. Refer to

EM-284, "Exploded View"

.

2.

Loosen exhaust manifold mounting nuts in the reverse order as
shown.

3.

Remove exhaust manifold.

INSTALLATION

1.

Exhaust gas temperature sensor 1

2.

Gasket

3.

Exhaust manifold

4.

Exhaust gas pressure sensor 1

A.

To cylinder head

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

JPBIA4802GB

JPBIA3039ZZ

EXHAUST MANIFOLD

EM-287

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1.

Tighten the mounting nuts in numerical order as shown.

2.

Install in reverse order of removal after this step.

Inspection

INFOID:0000000006449985

INSPECTION AFTER INSTALLATION

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

JPBIA3039ZZ

EM-288

< REMOVAL AND INSTALLATION >

[K9K]

OIL PAN

OIL PAN

Exploded View

INFOID:0000000006449986

Removal and Installation

INFOID:0000000006449987

REMOVAL

CAUTION:

Never drain engine oil when the engine is hot to avoid the danger of being scalded.

1.

Remove engine under cover.

2.

Remove RH front wheel. Refer to

WT-7, "Exploded View"

.

3.

Remove fender protector RH. Refer to

EXT-22, "Exploded View"

.

4.

Remove engine mounting bracket. Refer to

EM-326, "Exploded View"

.

5.

Remove center bearing bracket as shown.

JPBIA3125GB

1.

Baffle plate

2.

Gasket

3.

Oil pan

4.

O-ring

5.

Drain plug

6.

Oil level gauge guide

7.

Transaxle

8.

Crankshaft position sensor (POS)

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

MBIB1037E

OIL PAN

EM-289

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6.

Remove A/C compressor bracket mounting bolt as shown.

7.

Remove oil level gauge guide.

8.

Drain engine oil. Refer to

LU-34, "Draining"

.

CAUTION:

Perform when engine is cold.

9.

Remove oil pan and transaxle joint bolts.

10. Support the engine bottom of the oil pan with a transmission jack

etc.

11. Remove oil pan bolt reverse order as shown.

MBIB1038E

MBIB1039E

MBIB0575E

MBIB1257E

EM-290

< REMOVAL AND INSTALLATION >

[K9K]

OIL PAN

• Insert seal cutter (special service tool) between upper oil pan

and cylinder block. Slide tool by tapping on the side of the tool
with a hammer.

CAUTION:

Exercise care not to damage mating surface.

12. Remove oil pan and baffle plate.

INSTALLATION

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

1.

Apply liquid gasket as shown.
• Use Genuine Liquid Gasket or equivalent.

2.

Install baffle plate.

3.

Install oil pan.
• Tighten the mounting bolts of oil pan on the clutch housing without locking.
• Tighten the bolts in the numerical order shown in the figure.

• Tighten the mounting bolts of oil pan on the clutch housing.

4.

At least 30 minutes after oil pan is installed, pour engine oil.

SEM365EA

MBIB0593E

MBIB0594E

: 14 N·m (1.4 kg-m, 10 ft-lb)

MBIB1257E

: 44 N·m (4.5 kg-m, 10 ft-lb)

OIL PAN

EM-291

< REMOVAL AND INSTALLATION >

[K9K]

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Inspection

INFOID:0000000006449988

INSPECTION AFTER REMOVAL

Clean oil pump assembly if any object attached.

INSPECTION AFTER INSTALLATION

• Inspection the engine oil level. Refer to

LU-33, "Inspection"

.

• Start the engine, and make sure there is no leak of engine oil. Refer to

LU-33, "Inspection"

.

EM-292

< REMOVAL AND INSTALLATION >

[K9K]

GLOW PLUG

GLOW PLUG

Exploded View

INFOID:0000000006449989

Removal and Installation

INFOID:0000000006449990

REMOVAL

CAUTION:

Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.

1.

Disconnect the battery cable from the negative terminal.

2.

Remove cowl top extension. Refer to

EXT-20, "Exploded View"

.

3.

Remove engine under cover.

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 High pressure protection cover (upper). Refer to

EM-294, "Exploded View"

.

7.

Disconnect harness connector from glow plug.

8.

Remove glow plug.

CAUTION:

• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from

height of 10 cm (3.94 in) or higher, always replace it.]

INSTALLATION

1.

Remove adhered carbon from glow plug installation hole with a reamer.

2.

Install glow plug.

3.

Install remaining parts in reverse order of removal.

JPBIA3124GB

1.

Glow plug

Engine front

: N·m (kg-m, ft-lb)

VACUUM PUMP

EM-293

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VACUUM PUMP

Exploded View

INFOID:0000000006449991

Removal and Installation

INFOID:0000000006449992

REMOVAL

1.

Remove air cleaner case. Refer to

EM-280, "Exploded View"

.

2.

Disconnect vacuum hose from vacuum pump side.

3.

Remove damper valve bracket.

4.

Remove vacuum pump.

INSTALLATION

Install in the reverse order of removal.

Inspection

INFOID:0000000006449993

INSPECTION BEFORE REMOVAL

1.

Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
• Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connec-

tor.

2.

Start engine and measure generated vacuum at idle speed.

JPBIA3127GB

1.

Vacuum pump

2.

Gasket

3.

Damper valve bracket

4.

Vacuum hose

A.

To electric throttle control actuator

Engine front

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

Standard

: -86.6 to -101.3 kPa (-866 to -1,013 mbar, -650 to -760 mmHg, -25.59 to -29.92 inHg)

EM-294

< REMOVAL AND INSTALLATION >

[K9K]

INJECTION TUBE AND FUEL INJECTOR

INJECTION TUBE AND FUEL INJECTOR

Exploded View

INFOID:0000000006449994

Removal and Installation

INFOID:0000000006449995

REMOVAL

CAUTION:

• Be sure to read “Precautions for Diesel Equipment”. Refer to

EM-263, "Precaution for Diesel Equip-

ment"

.

• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• It is forbidden to open an injector. If you open an injector by mistake, you will have to change it.

This is because of the manufacturing and installation tolerances and because there is a risk of con-
taminating the inside of the injector.

• The rod filter of the injector must not be removed.
NOTE:
It is possible to replace a single injection tube.
1.

Disconnect the battery cable from negative terminal.

1.

Spill hose

2.

Injection tube

3.

Fuel injector

4.

Heat protection washer

5.

Fuel injector bracket

6.

Fuel injector bracket spacer

7.

Fuel rail stud bolt

8.

Fuel rail

9.

High pressure protection cover (low-
er)

10. Injection tube

11.

High pressure supply pump

12. High pressure protection cover (up-

per)

13. Oil level gauge guide

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA3040GB

INJECTION TUBE AND FUEL INJECTOR

EM-295

< REMOVAL AND INSTALLATION >

[K9K]

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2.

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

EM-281, "Exploded View"

.

3.

Remove oil level gauge guide and plug the hole.

4.

Remove injection tube protection cover.

5.

Remove the neck located on the fuel rail,
NOTE:
Undo the nut on the pump side or the injector side, then the nut located on the rail side. Undo the
nuts for each pipe in turn. Move the nut along the pipe keeping the olive in contact with the taper.

6.

Remove all the injection tubes.

7.

Plug all the holes in the injection circuit.

8.

Remove fuel rail.

9.

Disconnect fuel return pipe.

10. Manually remove the injector diesel return hose.

CAUTION:

Do not force on the diesel injector return hose

11. Plug all the holes of the injection circuit.
12. Disconnect the injector harness connector.

13. Unscrew the injector bracket.

14. Remove the injector.
15. Pull off the flame shield washer.

INSTALLATION

CAUTION:

All the injection tubes removed must be systematically replaced.

1.

Clean the injector sockets and the injector bodies, as well as their brackets using a lint-free cloth (use the
wipes recommended for this purpose, dipped in clean solvent.

2.

Dry off using a different new wipe.

3.

Replace the flame shield washer with a new one.

4.

Position the injector.

5.

Tighten its mounting bracket.

6.

Install injection tubes with new one.

7.

Finger tightens the nuts.

8.

Before fitting the new injection tubes, lightly lubricate the nut threads with the oil from the sachet provided
in the new parts kit.
NOTE:
Fit the pump/rail pipe before the rail/injector tubes.

9.

Fit the pump-rail injection tube as follow:
• Remove the protective plugs from the high pressure pump outlet, the high pressure rail inlet and the

pipe.

• Insert the injection tube olive into the taper of the high pressure pump outlet,
• Insert the injection tube olive into the taper of the high pressure rail inlet.
• Finger tighten the nuts of the injection tube starting with the one located on the rail side.

10. Install the rail-injector injection tube.

11. Tighten the injection tube nut.

12. Connect fuel return pipe.

13. Install in the reverse order to removal for the other refitting operations.

: 30.0 N·m (3.1 kg-m, 22 ft-lb)

: 24.0 N·m (2.4 kg-m, 18 ft-lb)

EM-296

< REMOVAL AND INSTALLATION >

[K9K]

5TH INJECTOR

5TH INJECTOR

Exploded View

INFOID:0000000006449996

Removal and Installation

INFOID:0000000006449997

REMOVAL

CAUTION:

• Be sure to read "Precautions for diesel equipment". Refer to

EM-263, "Precaution for Diesel Equip-

ment"

.

• Make preparations for coolant outflow.

1.

Remove air cleaner case. Refer to

EM-280, "Exploded View"

.

2.

Disconnect quick connector(1) and harness connector (2).

CAUTION:

• Be careful not to damage the connector.
• Be sure to read "Precautions for diesel equipment". Refer to

EM-263, "Precaution for Diesel Equip-

ment"

3.

Remove the following parts from the upper side of the engine.

1.

5th injector retaining bracket

2.

5th injector bolt

3.

5th injector

4.

Injector seal

5.

Diesel injector cooler

6.

Gasket

7.

Turbocharger outlet duct

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

JPBIA3032GB

JPBIA3077ZZ

5TH INJECTOR

EM-297

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• Remove fixing bolt (A) of 5th injector retaining bracket (1)
• Remove 5th injector retaining bracket (1).

4.

Remove the 5th injector (2) and injector seal. Refer to

EM-296,

"Exploded View"

INSTALLATION

1.

Clean the 5th injector:
• Immerse the 5th injector in a container of diesel.
• Wipe using clean cloth.

CAUTION:

Never clean the 5th injector with:
• A wire brush,
• An emery cloth,
• An ultrasonic cleaner.

2.

Always replace the injector seal.

3.

Install the 5th injector, injector seal and 5th injector retaining bracket assembly.

CAUTION:

Before tightening the 5th injector retaining bracket, check that the 5th injector is correctly positioned
in relation to the bracket.

4.

Install the other parts in the reverse order of the removal.

JPBIA3078ZZ

EM-298

< REMOVAL AND INSTALLATION >

[K9K]

HIGH PRESSURE SUPPLY PUMP

HIGH PRESSURE SUPPLY PUMP

Exploded View

INFOID:0000000006449998

Removal and Installation

INFOID:0000000006449999

REMOVAL

CAUTION:

• Be sure to read “Precautions for Diesel Equipment”. Refer to

EM-263, "Precaution for Diesel Equip-

ment"

.

• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• In case of the replacement of the high pressure supply pump

sprocket, please apply the following tightening torque:

1.

Disconnect the battery cable from the negative terminal.

2.

Remove cowl top extension. Refer to

EXT-20, "Exploded View"

.

3.

Remove turbocharger air inlet pipe. Refer to

EM-280, "Exploded View"

.

4.

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

EM-281, "Exploded View"

.

5.

Remove the timing belt. Refer to

EM-302, "Exploded View"

.

6.

Remove the neck located on the fuel rail,

7.

Remove the oil level gauge guide and plug the hole.

8.

Remove high pressure protection cover. Refer to

EM-294, "Exploded View"

.

9.

Carefully disconnect:
• The connectors from the flow actuator,
• The connectors from the fuel temperature sensor,
• On the pump, the fuel supply and return pipes.

1.

High pressure supply pump protector

2.

High pressure supply pump

: N·m (kg-m, ft-lb)

JPBIA3076GB

: 70.0 N·m (7.1 kg-m, 52 ft-lb)

MBIB9036E

HIGH PRESSURE SUPPLY PUMP

EM-299

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• The return pipe connecting the injectors with the pump.

10. Remove the injection tube connecting the pump to the rail. Refer to

EM-294, "Exploded View"

.

11. Plug all the holes of the injection circuit.

12. Remove the three mounting bolts from the high pressure supply pump then remove it.

INSTALLATION

1.

Install the pump then position the mounting bolts without tightening them.

2.

Before fitting the new injection tube, lightly lubricate the nut threads with the oil from the sachet provided
in the new parts kit.

3.

Refit the injection tube, to do this:
• remove the protective plugs,
• insert the injection tube olive into the taper of the high pressure pump outlet,
• insert the injection tube olive into the taper of the high pressure rail inlet.

4.

Finger tighten the nuts of the injection tube starting with the one located on the rail side.

5.

Tighten the mounting bolts on the high pressure pump.

6.

Tighten the injection tube nut.

7.

Refit high pressure supply pump protector.

CAUTION:

When refitting high pressure supply pump protector, follow steps below.
• Be sure disk rubber (1) is touching bolt head of high pres-

sure supply pump (2) as shown in the figure.

• Tighten bolt with holding protector towards to high pres-

sure supply pump.

• Make sure disk rubber (1) is touching with bolt head of

high pressure supply pump (2).

8.

Refit in the reverse order to removal for the other refitting operations.

9.

Test the sealing of the high pressure after it has been repaired (refer to “SPECIAL FEATURES” in

EM-

263, "Precaution for Diesel Equipment"

).

: 21.0 N·m (2.1 kg-m, 15 ft-lb)

: 24.0 N·m (2.4 kg-m, 18 ft-lb)

:21.0 N·m (2.1 kg-m, 15 ft-lb)

JPBIA3128ZZ