Juke F15 (2012 year). Service Repair Manual — part 200

EM-348

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

CYLINDER BLOCK

CHECKING PISTON PROTRUSION

1.

Clean the piston head.

2.

Turn the crankshaft one turn in its operating direction to bring
piston No. 1 close to TDC.

3.

Install Tool KV113B0050 (Mot. 252-01) (Commercial service
tool) or equivalent tool on the piston.

4.

Install Tool KV113B0040 (Mot. 251-01) (Commercial service
tool) or equivalent tool equipped with a gauge on support plate
KV113B0050 (Mot. 252-01) (Commercial service tool) or equiva-
lent tool, and find TDC.
NOTE:
All measurements must be carried out along the longitudinal
axis of the engine, in order to eliminate any errors due to tilting
of the piston.

WARNING:

The gauge follower must not be in the valve clearance.

5.

Inspect the piston protrusion which must be 0.099 to 0.285 mm
(0.0039 to 0.0112 in).

NO REGRINDING IS AUTHORIZED
Test the cylinder head to detect possible cracks using the cylinder
head test container (comprising a tray and a kit suited to the cylinder
head, plug, sealing plate and blanking plate).

INSTALLATION OF REAR OIL SEAL RETAINER AND OIL PUMP

MBIB0352E

Height of the cylinder head:

H = 127 mm (5.00 in)

Gasket face bow:

Cylinder head

: 0.05 mm (0.0020 in)

Cylinder block : 0.03 mm (0.0012 in)

MBIB0480E

MBIB0325E

MBIB0326E

CYLINDER BLOCK

EM-349

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

1.

Tighten the knock sensor.

2.

Tighten the oil pressure sensor.

3.

Install the oil pump sprocket and chain.

NOTE:
The gasket faces (cylinder block, rear oil seal retainer and
water pump) must be clean, dry and free from grease (in
particular, remove finger marks).
The rear oil seal retainer should be applied with liquid gas-
ket. The bead (A) must be 1.5 to 2 mm (0.059 to 0.079 in)
wide and be applied in accordance with the figure.
• Use Genuine Liquid Gasket or equivalent.

4.

Install the rear oil seal retainer. Tighten bolts (No.1 to 6) as
shown in the figure.

5.

Put a new gasket to water pump face and install the water
pump. Put a drop of locking sealant on the bolts (No.7 to 11) in
the numerical order as shown in the figure.

• Use Genuine thread locking sealant or equivalent.

NOTE:
The gasket faces (cylinder block and rear oil seal retainer)
must be clean, dry and free from grease (in particular,
remove finger marks).

6.

Apply four beads (B) of liquid gasket, with a diameter of 5 mm
(0.20 in).

7.

Apply two drops (C) of liquid gasket, with a diameter of 7 mm
(0.28 in) at the intersection of the rear oil seal retainer and the
cylinder block.
• Use Genuine Liquid Gasket or equivalent.

: 20 N·m (2.0 kg-m, 15ft-lb)

: 25 N·m (2.6 kg-m, 18ft-lb)

: 25 N·m (2.6 kg-m, 18ft-lb)

MBIB0442E

MBIB0481E

: 12 N·m (1.2 kg-m, 9ft-lb)

: 11 N·m (1.1 kg-m, 8ft-lb)

MBIB0482E

MBIB0483E

EM-350

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

CYLINDER BLOCK

8.

When installing the oil pan, ensure that the tabs (D) of the baffle
plate are correctly positioned in the slots (E).

9.

When installing the oil pan, ensure that the cylinder block and
the oil pan are correctly aligned on the flywheel side, to prevent
the clutch housing from being damaged when installing the tran-
saxle.

10. Install the baffle plate.

11. Install the oil pan, and tighten the bolts in the numerical order as

shown in the figure

INSTALLATION OF THE CRANKSHAFT SEAL GASKETS

1.

Crankshaft elastomer seal, timing side.

2.

Screw the threaded rod (A) of Tool KV113B0220 (Mot. 1586)
into the crankshaft.

3.

Position the spacer (B) of Tool KV113B0220 (Mot. 1586) on the
crankshaft.

MBIB0484E

MBIB0485E

: 14 N·m (1.4 kg-m, 10ft-lb)

MBIB1257E

MBIB0487E

MBIB0488E

CYLINDER BLOCK

EM-351

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

4.

Install the protector complete with the seal onto the spacer, tak-
ing care not to touch the seal.

5.

Install the cover (A) and the nut (B) (putting the threaded part
(C) of the nut on the side away from the engine) of Tool
KV113B0220 (Mot. 1586).

6.

Tighten the nut until the cover touches the spacer.

7.

Remove the nut, the cover, the protector and the threaded rod.

MBIB0489E

MBIB0490E

MBIB0491E

MBIB0492E

MBIB0493E

EM-352

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

CYLINDER BLOCK

8.

Crankshaft elastomer seal, flywheel side.

9.

Install Tool KV113B0210 (Mot. 1585) on the crankshaft, securing
it with bolts (F).

10. Put the protector complete with the seal on Tool KV113B0210

(Mot. 1585), being careful not to touch the seal.

11. Install the cover (G) and nut (H) (putting the threaded part (I) of

the nut on the side away from the engine) of Tool KV113B0210
(Mot. 1585).

12. Tighten the nut until the cover touches the cylinder block.

MBIB0494E

MBIB0495E

MBIB0496E

MBIB0497E

MBIB0498E

CYLINDER BLOCK

EM-353

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

13. Remove the nut, the cover, the protector and the threaded rod.

14. Install Tool KV113B0060 (Mot. 582-01) and tighten the new

bolts.

15. Install the clutch housing, tightening the bolts to the torque.

16. Remove Tool KV113B0060 (Mot. 582-01).

METHOD FOR INSTALLING THE OIL COOLER AND OIL FILTER

1.

Install oil cooler. Refer to

LU-37, "Exploded View"

.

2.

Install oil filter. Refer to

LU-35, "Exploded View"

.

Inspection

INFOID:0000000006450013

PISTON MARKING

TABLE OF PISTON PIN HEIGHT

MBIB0499E

: 50 - 60 N·m (5.1 - 6.1 kg-m, 37 - 44 ft-lb)

MBIB0500E

M6 bolt

: 13 - 16 N·m

(1.3 - 1.6 kg-m, 10 - 12 ft-lb)

M7 bolt

: 18 - 22 N·m

(1.8 - 2.2 kg-m, 13 - 16 ft-lb)

MBIB0501E

1

Direction of fitting of the piston mark towards the flywheel

2

Height between the piston pin and the top of the piston (see
table below).

3

Used by the supplier only

4

Used by the supplier only

5

Used by the supplier only

6

Piston axis of symmetry

7

Piston pin hole axis

8

Offset between the hole axis (7) and the piston's axis of sym-
metry (6) is 0.3 mm (0.012 in)

MBIB0337E

EM-354

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

CYLINDER BLOCK

Unit: mm (in)

The tolerance on the piston pin heights is

±

0.02 mm (

±

0.0008).

* The different piston pin heights are exclusively reserved for the engine assembly plant.
The service parts will only supply piston classes (height) L, M, N.
NOTE:
• If the engine is installed with a K class piston, an L class piston must be installed as a replacement.
• If the engine is installed with a P class piston, an N class piston must be installed as a replacement.

MEASURING THE PISTON DIAMETER

The piston diameter must be measured at height A = 56 mm (2.20
in).

PISTON RING

The piston rings are supplied ready adjusted.

PISTON RING END GAP

CONNECTING ROD

* Mark on piston

Piston pin height

K

41.667 (1.6404)

L

41.709 (1.6421)

M

41.751 (1.6437)

N

41.793 (1.6454)

P

41.835 (1.6470)

Piston diameter

: 75.933 - 75.947 mm (2.9895 -
2.9900 in)

Piston pin:

Length

: 59.7 - 60.3 mm (2.350 - 2.374 in)

Outer diameter

: 24.8 - 25.2 mm (0.976 - 0.992 in)

Inner diameter

: 13.55 - 13.95 mm (0.5335 -
0.5492 in)

MBIB0338E

Thickness:

Top ring

: 1.97 - 1.99 mm (0.0776 - 0.0783 in)

2nd ring

: 1.97 - 1.99 mm (0.0776 - 0.0783 in)

Oil ring

: 2.47 - 2.49 mm (0.0972 - 0.0980 in)

MBIB0339E

Top ring

: 0.20 - 0.35 mm (0.0079 - 0.0138 in)

2nd ring

: 0.70 - 0.90 mm (0.0276 - 0.0354 in)

Oil ring

: 0.25 - 0.50 mm (0.0098 - 0.0197 in)

CYLINDER BLOCK

EM-355

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

The connecting rod is of the detachable cap type.

WARNING:

• The bolts must be coated with engine oil under the heads and

on the threads when the connecting rods are installed in the
engine.

• The big end caps are positioned on the connecting rod by

irregularities on the parting line.

• The occurrence of impacts or a foreign body between the

body - cap mating surfaces will lead to rapid rupture of the
connecting rod.

NOTE:
The connecting rod small end rings cannot be replaced.
The maximum weight difference for the connecting rod, piston and
piston pin assemblies for the same engine must be 0.245 N (25 g,
0.88 oz).

WARNING:

• To avoid initiating a crack in the connecting rod, Never use a

sharp point to mark the big end caps in relation to their con-
necting rod.

• Use a permanent marker pen.

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

DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON

Lateral big end play

: 0.205 - 0.467 mm (0.0081 -
0.0184 in)

Diametrical big end play

: 0.035 - 0.045 mm (0.0014 -
0.0018 in)

Center distance between
the big end and small end

: 133.75 mm (5.2657 in)

Diameter of the big end

: 47.610 - 47.628 mm (1.8744 -
1.8751 in)

Diameter of the small end

(without ring)

: 27.24 - 27.26 mm (1.0724 -
1.0732 in)

(with ring)

: 25.013 - 25.025 mm (0.9848 -
0.9852 in)

MBIB0340E

MBIB0341E

MBIB0342E

EM-356

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

CYLINDER BLOCK

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

and installation channel (D).

CRANKSHAFT

• The lateral shims are located on bearing No. 3.
• No rectifications are allowed.

WORKING OUT THE CLASS OF MAIN BEARING (ORIGINAL FITMENT)

Marking (A) On The Crankshaft

• Detail of the marking (A):

Number of journals

* Flywheel end.

Table Of Journal Diameter Classes

Unit: mm (in)

CYLINDER BLOCK

ENGINE IDENTIFICATION

MBIB0343E

Number of main journals

: 5

Crankshaft side clearance:

Without wear on side shims

: 0.045 - 0.252 mm (0.0018 - 0.0099 in)

With wear on side shims

: 0.045 - 0.852 mm (0.0018 - 0.0335 in)

Crankshaft diametrical clearance:

Journals

: 0.027 - 0.054 mm (0.0011 - 0.0021 in)

Crankshaft pins

: 0.035 - 0.045 mm (0.0014 - 0.0018 in)

Journal diameter:

: 47.99 - 48.01 mm (1.8894 - 1.8902 in)

Crankshaft pin diameter:

: 43.96 - 43.98 mm (1.7307 - 1.7315 in)

1*

2

3

4

5

Classes of
journal di-
ameters
A = D1
B = D2
C = D3

B

B

C

C

B

MBIB0344E

Journal class mark on the crankshaft

Journal diameter

A = D1

47.990 - 47.996 (1.8894 - 1.8896)

B = D2

47.997 - 48.003 (1.8896 - 1.8899)

C = D3

48.004 - 48.010 (1.8899 - 1.8902)

CYLINDER BLOCK

EM-357

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

The diameters of the bearings (A) of the cylinder block are marked
by a hole on the block (B) located above the oil filter.

ENGINE IDENTIFICATION

Identification is by means of an engraved plate on the cylinder block
which carries:
• A: engine type
• B: engine type approval letter
• D: code
• E: engine suffix
• F: engine serial number
• G: engine assembly plant

TABLE OF CYLINDER BLOCK MAIN BEARING HOUSING INNER DIAMETERS

NOTE:
The marking zone includes:

MBIB0345E

MBIB0346E

MBIB0322E

Hole position (B)

Class reference

Cylinder block main bearing housing inner

diameter

X = 33 mm (1.30 in)

1 or blue

51.936 - 51.942 mm

(2.0447 - 2.0450 in)

Y = 43 mm (1.69 in)

2 or red

51.942 - 51.949 mm

(2.0450 - 2.0452 in)

EM-358

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

CYLINDER BLOCK

• X - Y gives the diameter class of bearings A or B.

MATCHING THE MAIN BEARING

* Cylinder block main bearing diameter class.

NOTE:
The service parts will only supply class C2 (blue).

Journal diameter class

D1

D2

D3

1*

C1

1.949 - 1.955 mm

(0.0767 - 0.0770 in)

yellow

C2

1.946 - 1.952 mm

(0.0766 - 0.0769 in)

blue

C3

1.943 - 1.949 mm

(0.0765 - 0.0767 in)

black

2*

C4

1.953 - 1.959 mm

(0.0769 - 0.0771 in)

red

C1

1.949 - 1.955 mm

(0.0767 - 0.0770 in)

yellow

C2

1.946 - 1.952 mm

(0.0766 - 0.0769 in)

blue

Bearing thickness and class

SERVICE DATA AND SPECIFICATIONS (SDS)

EM-359

< SERVICE DATA AND SPECIFICATIONS (SDS)

[K9K]

C

D

E

F

G

H

I

J

K

L

M

A

EM

N

P

O

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specification

INFOID:0000000006450014

Tightening torque

INFOID:0000000006450015

UPPER ENGINE

Unit: N·m (kg-m, ft-lb)

*1: Refer to tightening procedure in the text.

BOTTOM ENGINE

Engine

Compres-

sion ratio

Bore and

stroke mm (in)

Displacement

cm

3

(cu in)

Compression

pressure kPa

(bar, kg/cm

2

, psi)

K9K

18.25/1

76 x 80.5

(2.992 x 3.169)

1,461 (89.15)

Maximum pressure
must be least 1,800
(18, 18.36, 261)

Tightening torque

Cylinder head

: *1

Camshaft bracket

: 11 (1.1, 8)

Vacuum pump

: 21 (2.1, 15)

Cylinder head coolant outlet unit

: 11 (1.1, 8)

Exhaust manifold

: 26 (2.7, 19)

Glow plug

: 15 (1.5, 11)

Rocker cover

: 12 (1.2, 9)

Turbocharger-manifold mounting

: 26 (2.7, 19)

Turbocharger oil return pipe

: 12 (1.2, 9)

Turbocharger oil supply pipe

: 23 (2.3, 17)

Timing tensioner

: 27 (2.8, 20)

TDC cap

: 20 (2.0, 15)

Cylinder head suspended mounting bracket

: 21 (2.1, 15)

EM-360

< SERVICE DATA AND SPECIFICATIONS (SDS)

[K9K]

SERVICE DATA AND SPECIFICATIONS (SDS)

Unit: N·m (kg-m,ft-lb)

*1: Refer to tightening procedure in the text.

Tightening torque

Oil cooler connector bolt

: 45 (4.6, 33)

Oil filter bracket

: 45 (4.6, 33)

Main bearing cap

: 25 (2.6, 18) + 47

°±

6

°

(Angle tightening)

Connecting rod

: 20 (2.0, 15) + 45

°±

6

°

(Angle tightening)

Knock sensor

: 20 (2.0, 15)

Oil level sensor

: 25 (2.6, 18)

Oil pump

: 25 (2.6, 18)

Oil pan

: *1

Water pump

: 11 (1.1, 8)

Flywheel

: 50 - 55 (5.1 - 5.6, 37 - 40)

Crankshaft pulley

: 60 (6.1, 44) + 100

°±

10

°

(Angle tightening)/M12 bolt.

:120 (12, 89) + 95

°±

15

°

(Angle tightening)/M14 bolt.

Water pump inlet pipe

: 22 (2.2, 16)

Alternator bracket

: 44 (4.5, 32)

Alternator

: 21 (2.1,15) for engine number < D051474,

: 25 (2.6, 18) for engine number

≥

D051474

A/C compressor

: 21 (2.1, 15)

EX-1

ENGINE

C

D

E

F

G

H

I

J

K

L

M

SECTION

EX

A

EX

N

O

P

CONTENTS

EXHAUST SYSTEM

MR16DDT

PRECAUTION . . . . . . . . . . . ...

2

PRECAUTIONS . . . . . . . . . . . . ...

2

Removal and Installation . . . . . . . . . . ...

2

PREPARATION . . . . . . . . . . .

3

PREPARATION . . . . . . . . . . . . ...

3

Special Service Tools . . . . . . . . . . . ....

3

Commercial Service Tools . . . . . . . . . ....

3

PERIODIC MAINTENANCE . . . . . . ..

4

EXHAUST SYSTEM . . . . . . . . . . .

4

Inspection . . . . . . . . . . . . . . . . ..

4

REMOVAL AND INSTALLATION . . . .

5

EXHAUST SYSTEM . . . . . . . . . . .

5

Exploded View . . . . . . . . . . . . . . ..

5

Removal and Installation . . . . . . . . . . ...

6

Inspection . . . . . . . . . . . . . . . . ..

7

HR16DE

PRECAUTION . . . . . . . . . . . ...

9

PRECAUTIONS . . . . . . . . . . . . ...

9

Removal and Installation . . . . . . . . . . ...

9

PREPARATION . . . . . . . . . . ...

10

PREPARATION . . . . . . . . . . . . .

10

Special Service Tools . . . . . . . . . . . ..

10

Commercial Service Tools . . . . . . . . . ...

10

PERIODIC MAINTENANCE . . . . . .

11

EXHAUST SYSTEM . . . . . . . . . . ..

11

Inspection . . . . . . . . . . . . . . . .

11

REMOVAL AND INSTALLATION . . . ...

12

EXHAUST SYSTEM . . . . . . . . . . ..

12

Exploded View . . . . . . . . . . . . . . .

12

Removal and Installation . . . . . . . . . . .

12

Inspection . . . . . . . . . . . . . . . .

14

K9K

PRECAUTION . . . . . . . . . . . ..

15

PRECAUTIONS . . . . . . . . . . . . .

15

Removal and Installation . . . . . . . . . . .

15

PERIODIC MAINTENANCE . . . . . .

16

EXHAUST SYSTEM . . . . . . . . . . ..

16

Inspection . . . . . . . . . . . . . . . .

16

REMOVAL AND INSTALLATION . . . ...

17

EXHAUST SYSTEM . . . . . . . . . . ..

17

Exploded View . . . . . . . . . . . . . . .

17

Removal and Installation . . . . . . . . . . .

17

Inspection . . . . . . . . . . . . . . . .

18

EX-2

< PRECAUTION >

[MR16DDT ]

PRECAUTIONS

PRECAUTION

PRECAUTIONS

Removal and Installation

INFOID:0000000006356452

CAUTION:

• Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat

resistance, corrosion resistance, and shape.

• Perform the operation with the exhaust system fully cooled down because the system will be hot

just after engine stops.

• Be careful not to cut your hand on the heat insulator edge.

PREPARATION

EX-3

< PREPARATION >

[MR16DDT ]

C

D

E

F

G

H

I

J

K

L

M

A

EX

N

P

O

PREPARATION

PREPARATION

Special Service Tools

INFOID:0000000006356453

Commercial Service Tools

INFOID:0000000006356454

Tool number
Tool name

Description

KV10114400
Heated oxygen sensor wrench

Loosening or tightening heated oxygen sen-
sor 2
a: For 22 mm (0.87 in) width hexagon nut

S-NT636

Tool name

Description

Power tool

Loosening nuts and bolts

Heated oxygen sensor thread cleaner

Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
A: J-43897-18 [18 mm (0.71 in) dia.] for zir-
conia heated oxygen sensor
B: J-43897-12 [12 mm (0.47 in) dia.] for tita-
nia heated oxygen sensor
C: Mating surface shave cylinder
D: Flutes

Anti-seize lubricant (Permatex 133AR
or equivalent meeting MIL specifica-
tion MIL-A-907)

Lubricating heated oxygen sensor thread
cleaner when reconditioning exhaust system
threads

PBIC0190E

JPBIA0238ZZ

AEM489