Juke F15 (2012 year). Service Repair Manual — part 199

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POSITIONING THE BELT AT THE TIMING POINT

1.

Rotate the crankshaft clockwise, until the position (A) of the
camshaft pulley becomes opposite of the position (B) on the cyl-
inder head.

2.

Insert TDC set pin [SST: KV 113B0110 (Mot. 1430)] (A) into the
camshaft pulley and cylinder head.

3.

Screw in the Tool KV113B0130 (Mot. 1489).

4.

Turn the engine clockwise (timing side) until the crankshaft
reaches the Tool KV113B0130 (Mot. 1489).

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5.

The Tool KV113B110 (Mot. 1430) (A) must engage in the cam-
shaft pulley and cylinder head holes.

6.

Remove Tool KV113B0130 (Mot. 1489).

7.

Install the Tool KV113B0060 (Mot. 582-01).

8.

Remove the crankshaft pulley (1).

9.

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

10. Remove the timing belt tensioner and inner timing cover.

11. Remove air cleaner case. Refer to

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.

12. Remove the turbocharger oil supply pipe (A) on the cylinder

head side.

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13. Remove the turbocharger oil supply pipe on the turbocharger

side, nuts (A) and the torx bolt of the turbocharger flange, and
turbocharger oil outlet hose (1).

14. Unclip the fuel return pipe from the cylinder head cover at the

fuel spill tube (1), then remove the rocker cover (2).

15. Remove the oil level gauge guide and cylinder head.

CLEANING

• It is very important not to scratch the gasket faces of any aluminium components.
• Use suitable tool to dissolve any part of the seal which remains stuck to the metal surface.
• Apply the dissolving product to the part to be cleaned, wait approximately 10 minutes, then remove it using a

wooden spatula.

• Wear gloves while carrying out this operation.
• Do not allow this dissolving product to drip on to the paintwork.
• Great care should be taken when performing this operation, to prevent foreign objects from entering

the pipes taking oil under pressure to the camshafts (pipes in both the cylinder head and its cover)
and the oil return pipes.

• Failure to follow these instructions could lead to the blocking of the oilways, resulting in rapid and

serious damage to the engine.

DISASSEMBLY OF THE BOTTOM ENGINE

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1.

Install the Tool KV113B0060 (Mot. 582-01).

2.

Remove the clutch housing.

3.

Remove the flywheel.

4.

Remove the oil pan bolt in reverse order as shown.

5.

Remove the baffle plate.

6.

Remove the oil level sensor.

7.

Remove the oil pump.

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8.

Remove the rear oil seal retainer.

9.

Remove the water pump.

10. Remove the oil pump chain.
11. Remove the oil pump drive sprocket.

WARNING:

Never use a sharp point to mark the bearing caps in relation
to their connecting rods to avoid starting a crack in the rod.
Use a permanent marker pen.

12. Remove the big end cap bolts and the connecting rod/piston

assemblies.
NOTE:
It is essential to mark the position of the main bearing cap,
as the category may be different for each bearing.

13. Remove the main bearing caps.
14. Remove the crankshaft.

15. Remove the oil pressure switch, the knock sensor and oil filter

bracket connecting bolt.

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16. Remove the oil cooler connecting bolt.

REMOVING THE PISTON PINS

NOTE:
It is imperative to mark the connecting rod to match it to its piston, because the piston height classes
in the same engine may be different (see Technical Specifications section).
To remove the piston pin, remove the snap ring using a screwdriver, then release the pin.

CONNECTING ROD BEARING

• The connecting rod bearing are installed using Tool KV113B0140

(Mot. 1492) and Tool KV113B0150 (Mot. 1492-03).

ON THE CONNECTING ROD BODY

1.

Slide the connecting rod bearing support (A) of Tool
KV113B0150 [Mot. 1492-03 (positioning the engraved mark (B)
as shown in the figure)] into the groove (C) of the base of Tool
KV113B0140 (Mot. 1492).

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2.

Install the guide (D) of Tool KV113B0150 (Mot. 1492-03) onto
the base (as shown in the figure).

3.

Lay the body of the connecting rod on the base of the tool (as
shown in the diagram). Check that the lower part (E) of the small
end is touching the centering pin and push the guide (G) in the
direction of the arrow.

4.

Lay the connecting rod bearing [with a width of 20.625 mm
(0.8120 in)] (F) on the connecting rod bearing support, then
push it in the direction of the arrow (as shown in the figure).

5.

Bring the connecting rod support up against the base of the con-
necting rod body.

6.

Remove the connecting rod body support and repeat the opera-
tion for the remaining connecting rod bodies.

ON THE CONNECTING ROD CAP

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1.

Position the connecting rod bearing support either on the
engraved mark (C) if the width of the connecting rod bearing is
equal to 20.625 mm (0.8120 in).

2.

Position the connecting rod bearing support either on the
engraved mark (D) if the width of the connecting rod bearing is
equal to 17.625 mm (0.6939 in).

3.

Install the connecting rod cap as shown in the figure.

4.

Push the guide (in the direction of the arrow) until the connecting
rod cap is in contact with the pins (I) on the base of the tool.

5.

Install the connecting rod bearing (H) on the bearing support,
then push it in the direction of the arrow (as shown in the figure).

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6.

Bring the connecting rod bearing support up against the base of
the connecting rod cap.

7.

Remove the connecting rod bearing support and repeat the
operation for the remaining connecting rod caps.

REPLACEMENT OF THE OIL JETS

Removal

1.

To remove the oil jets (A), they must be drilled with a 7 mm (0.28
in) diameter drill. This is necessary in order to remove the spring
stop (B) and the spring (C).

NOTE:
Do not remove the ball (D) to prevent from entering the
cooling circuit.

2.

Remove the chippings and spring using a suitable brush.

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3.

Screw Tool KV113B0120 (Mot. 1485-01) in the drilled out jets
using a 6 mm (0.24 in) Allen key which must slide into the tool.

4.

Screw Tool KV113B0020 (Emb. 880) onto KV113B0120 (Mot.
1485-01) and remove the oil jet.

ASSEMBLY

INSTALLATION OF OIL JETS

Installation of The Oil Jets For No.1 and No.3 Cylinders

1.

Install plate (A) of Tool KV113B0170 (Mot. 1494) onto the cylin-
der block (as shown in the figure) without tightening the two
bolts (C).

2.

Position the guide rod (B) in the plate (A) and the end of the
guide rod in the hole of the oil jet to center the plate (A).

3.

Tighten the two bolts (C).

4.

Remove the guide rod.

5.

Install the push rod instead of the guide rod, then insert the oil jet
into the push rod.
NOTE:
Check that the oil jet is correctly oriented with the end of
the jet (D) directed towards the center of the cylinder.

6.

The oil jets must be installed using Tool KV113B0170 (Mot. 1494).

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7.

With a hammer, tap the push rod until the shoulder (E) of the
push rod comes into contact with the plate (A).

Installation of The Oil Jets For No.2 and No.4 Cylinders

1.

Fit plate (A) of Tool KV113B0170 (Mot. 1494) onto the cylinder
block (as shown in the figure) without tightening the two bolts
(C).

2.

Position the guide rod (B) in the plate (A) and the end of the
guide rod in the hole of the oil jet to center the plate (A).

3.

Tighten the two bolts (C).

4.

Remove the guide rod.

5.

Position the push rod instead of the guide rod, then insert the oil
jet into the push rod.
NOTE:
Check that the oil jet is correctly oriented with the end of
the jet (D) directed towards the center of the cylinder.

6.

With a hammer, tap the push rod until the shoulder (E) of the
push rod comes into contact with the plate (A).

Orientation Of The Oil Jets (See Diagram Below)

• Clean the cylinder block and crankshaft by passing a wire through the lubrication channels.

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INSTALLATION OF MAIN BEARING

1.

Position the grooved main bearings on the cylinder block.

2.

Install the smooth bearings on the bearing caps.

MAIN BEARING

• The engine is installed with main bearing without a locator

notch.

1.

The main bearings are installed on the cylinder block and on the
bearings using Tool KV113B0160 (Mot. 1493-01).

A

Orientation of the oil jets of No. 2 and No. 4 cylinders

B

Orientation of the oil jets of No. 1 and No. 3 cylinders

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2.

For direction of installation on the cylinder block, install grooved
main bearing on all the bearings.

3.

For direction of installation on the bearing caps, install non-
grooved main bearing.

ON THE CYLINDER BLOCK

1.

Position tool KV113B0160 (Mot. 1493-01) on the cylinder block.

2.

Press at (A) until the bearing cap is touching at (B) with
KV113B0160 (Mot. 1493-01).

ON THE BEARING CAPS

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1.

Position Tool KV113B0160 (Mot. 1493-01) on the bearing cap.

2.

Install the main bearing in Tool KV113B0160 (Mot. 1493-01),
then press at (A) until the main bearing is touching at (B) with
Tool KV113B0160 (Mot. 1493-01).

3.

Oil the main bearing.

4.

Install the crankshaft.

5.

Install the lateral shims on bearing No. 3, putting the grooves on
the crankshaft side.

6.

Install the main bearing caps on bearing cap No. 1 (these are
numbered from 1 - 5 and these numbers should be positioned
opposite the water pump), and tighten the bolts as follows:

a.

Tighten the bolts.

b.

Turn the bolt 47 degrees

±±

6 degrees clockwise (angle tightening).

7.

Check the lateral clearance of the crankshaft which should be
without wear on lateral shims: 0.045 - 0.252 mm (0.0018 -
0.0099 in)

8.

Check the lateral clearance of the crankshaft which should be
with wear on the lateral shims: 0.045 - 0.852 mm (0.0018 -
0.0335 in)

INSTALLATION OF NO. 1 BEARING

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1.

Degrease the gasket faces (of the cylinder block and bear-
ing No. 1). They should be clean, dry and free from grease
(in particular, remove finger marks).

2.

Lay two beads of liquid sealant with a width of 1 mm (0.04 in) on
bearing No. 1 of the cylinder block.
Tighten the bolts of bearing cap No. 1, and tighten the bolts as
follows:

a.

Tighten the bolts.

b.

Turn the bolt 47 degrees

±±

6 degrees clockwise (angle tighten-

ing).

CONNECTING RODS / PISTON ASSEMBLY

• The pistons have a mark engraved on their heads indicating the engine rear side.

1.

Oil the piston pin.

2.

Check that the piston pins rotate correctly in the new piston and in the matching connecting rod.

Direction Of Installation Of The Connecting Rod In Relation To The Piston

• Point the mark (A) engraved on the top of the piston upwards and

the flat (B) of the big end downwards as shown in the figure.

DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON

• Position the opening (C) of the snap rings opposite the removal

and fitting channel (D).

INSTALLATION OF THE SNAP RINGS

1.

Rings set to their original adjustment must be free within their channels.

2.

Ensure the snap rings are fitted the correct way, with the word TOP pointing upwards.

Orientation Of The Piston Rings In The Piston

: 25 N·m (2.6 kg-m, 18 ft-lb)

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1.

Ensure the break in each piston ring is correctly oriented as
shown in the figure.

2.

Apply new engine oil to the pistons.

3.

Install the connecting rod/piston assemblies into the cylinder
block using the ring, being careful to fit them the right way round
(mark towards the flywheel).

4.

Install the connecting rods onto the oiled crankshaft pins of the
crankshaft.

5.

Install the connecting rod caps, ensuring they are correctly
matched.

6.

Tighten the big end cap bolts to a torque of 20 N·m (2.0 kg-m, 15
ft-lb), plus an angle tightening of 45

°±

6

°

.

7.

Inspect that the big ends have the correct lateral clearance of 0.205 to 0.467 mm (0.0081 to 0.0184 in).

CONNECTING ROD BEARING

• The engine is installed with connecting rod bearing without a

locator notch.
NOTE:
The upper and lower connecting rod bearing are not the same
width.

• The connecting rod bearing are installed using Tool KV113B0140

(Mot. 1492) and Tool KV113B0150 (Mot. 1492-03).

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: 20 N·m (2.0 kg-m, 15ft-lb)

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Connecting rod bearing width:

Upper bearing

: 20.625 mm (0.8120 in)

Lower bearing

: 17.625 mm (0.6939 in)

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