Juke F15 (2012 year). Service Repair Manual — part 188

EM-156

< PERIODIC MAINTENANCE >

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DRIVE BELT

• Perform the belt tension adjustment with the lock nut temporarily tightened at the step “1” so as

not to tilt the idler pulley.

• When checking immediately after installation, first adjust it to the specified value. Then, after

turning crankshaft two turns or more, readjust to the specified value to avoid variation in deflec-
tion between pulleys.

4.

Tighten the lock nut.

5.

Check that belt tension of each belt within the standard.

: 34.8 N·m (3.5 kg-m, 26 ft-lb)

AIR CLEANER FILTER

EM-157

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AIR CLEANER FILTER

Exploded View

INFOID:0000000006449892

Removal and Installation

INFOID:0000000006449893

REMOVAL

1.

Remove the assembly consisting of element case, air cleaner case, and inlet air duct (upper).

2.

Remove the air cleaner filter case.

1.

Hose clamp

2.

PCV hose

3.

Hose clamp

4.

Air cleaner filter

5.

Air cleaner filter case

6.

Grommet

7.

Inlet Air duct (lower)

8.

Grommet

9.

Inlet Air duct (upper)

10. Bracket

11.

Air cleaner case

12. O-ring

13. Mass air flow sensor

14. Air duct

A.

To electric throttle control actuator

B.

To rocker cover

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

JPBIA4089GB

EM-158

< PERIODIC MAINTENANCE >

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AIR CLEANER FILTER

3.

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

INSTALLATION

Note the following, and install in the reverse order of removal.
• Check by the feel and the sound that both pawls of the air cleaner case are securely fastened to the element

case.

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SPARK PLUG

EM-159

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SPARK PLUG

Removal and Installation

INFOID:0000000006449894

REMOVAL

1.

Remove ignition coil. Refer to

EM-178, "Exploded View"

.

2.

Remove spark plug with a spark plug wrench (commercial ser-
vice tool).

CAUTION:

Never drop or shock spark plug.

INSTALLATION

Install in the reverse order of removal.

Inspection

INFOID:0000000006449895

INSPECTION AFTER REMOVAL

Use the standard type spark plug for normal condition.

CAUTION:

• Never drop or shock spark plug.
• Never use a wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be

used.

a

: 14 mm (0.55 in)

JPBIA0030ZZ

Spark plug (Standard type)

: Refer to

EM-251, "Spark Plug"

.

Cleaner air pressure

: Less than 588 kPa (6 kg/cm

2

,

85 psi)

Cleaning time

: Less than 20 seconds

SMA773C

EM-160

< REMOVAL AND INSTALLATION >

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DRIVE BELT IDLER PULLEY

REMOVAL AND INSTALLATION

DRIVE BELT IDLER PULLEY

Removal and Installation

INFOID:0000000006449896

REMOVAL

1.

Remove drive belt. Refer to

EM-155, "Removal and Installation"

.

2.

Remove the lock nut, and then remove the plate (7), idler pulley
(6), and washer (5).

3.

Remove the center shaft (2) together with the spacer (3) with
inserting the adjusting bolt (4).

INSTALLATION

1.

Insert the center shaft (1) into the slide groove of the spacer (2).
Fully screw in the adjusting bolt (3) in the belt loosening direc-
tion (

).

• At that time, place the flange (a) of the adjusting bolt and the

seat (b) of the center shaft on the spacer.

2.

Place each surface (c and d) of the spacer on the alternator
bracket. Install the washer, idler pulley, and plate, and then tem-
porarily tighten the lock nut.

3.

Install removed parts in the reverse order of removal.

1

: Alternator bracket

PBIC3644E

: 4.4 N·m (0.45 kg-m, 39 in-lb)

PBIC3885E

AIR CLEANER AND AIR DUCT

EM-161

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AIR CLEANER AND AIR DUCT

Exploded View

INFOID:0000000006449897

Removal and Installation

INFOID:0000000006449898

REMOVAL

NOTE:
Mass air flow sensor is removable under the car-mounted condition.

1.

Remove the clip of front fender protector (left) to lift the front fender protector.

2.

Remove the front side glille (left) from front bumper.

3.

Remove installing bolts from inlet air duct (lower).

4.

Disconnect mass air flow sensor harness connector.

5.

Loosen the hose clamp of air duct.

6.

Remove installing bolts from air cleaner case.

7.

Remove inlet air duct (upper) and air cleaner simultaneously.

1.

Hose clamp

2.

PCV hose

3.

Hose clamp

4.

Air cleaner filter

5.

Air cleaner filter case

6.

Grommet

7.

Inlet air duct (lower)

8.

Grommet

9.

Inlet air duct (upper)

10. Bracket

11.

Air cleaner case

12. O-ring

13. Mass air flow sensor

14. Air duct

A.

To electric throttle control actuator

B.

To rocker cover

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

JPBIA4089GB

EM-162

< REMOVAL AND INSTALLATION >

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AIR CLEANER AND AIR DUCT

8.

Remove inlet air duct (lower)

9.

.Disconnect PCV hose.

10. Remove air duct.

11. Remove mass air flow sensor from air cleaner case, if necessary.

CAUTION:

Handle the mass air flow sensor with following cares.
• Never shock the mass air flow sensor.
• Never disassemble the mass air flow sensor.
• Never touch the sensor of the mass air flow sensor.

INSTALLATION

Note the following, and install in the reverse order of removal.
• To install air duct, align the matching marks on both ends with the

others.

• Align marks. Attach each joint. Screw clamps firmly.

• Install PVC hose with each matching mark positioned as follows:

Inspection

INFOID:0000000006449899

INSPECTION AFTER REMOVAL

Inspect air duct for crack or tear.
• If anything found, replace air duct.

1.

: Electric throttle control actuator

2.

: Air cleaner case

A.

: Matching mark

JPBIA4122ZZ

Clamp tightening torque

: 4.5 N·m (0.46 kg-m)

A

: White mark

B

: Matching mark

Air duct side

: Align the matching mark with that of air duct side.

Rocker cover side

: Face the white mark in forward direction of the vehi-
cle.

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INTAKE MANIFOLD

EM-163

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INTAKE MANIFOLD

Exploded View

INFOID:0000000006449900

Removal and Installation

INFOID:0000000006449901

REMOVAL

1.

Drain engine coolant. Refer to

CO-11, "Draining"

.

CAUTION:

• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.

2.

Remove air duct (inlet) and air duct assembly. Refer to

EM-161, "Exploded View"

.

3.

Remove reservoir tank.

4.

Pull out oil level gauge.

CAUTION:

Cover the oil level gauge guide openings to avoid entry of foreign materials.

5.

Disconnect water hoses from electric throttle control actuator as follows:
• Drain engine coolant from radiator or attach plug to prevent engine coolant leakage when engine cool-

ant is not drained. Refer to

CO-11, "Draining"

.

1.

EVAP canister purge volume control
solenoid valve

2.

Hose clamp

3.

Vacuum hose

4.

Intake manifold support

5.

Gasket

6.

Intake manifold

7.

Electric throttle control actuator

8.

Gasket

A.

To air cleaner

B.

To centralized under-floor piping

C.

To brake booster

D.

To rocker cover

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

JPBIA4090GB

EM-164

< REMOVAL AND INSTALLATION >

[HR16DE]

INTAKE MANIFOLD

CAUTION:

Perform this step when the engine is cold.

6.

Remove electric throttle control actuator.

CAUTION:

• Handle carefully to avoid any shock to electric throttle control actuator.
• Never disassemble electric throttle control actuator.

7.

Disconnect harness connector and vacuum hose from purge control solenoid valve.

CAUTION:

Never impact it.

8.

Disconnect vacuum hose for brake booster from intake manifold.

9.

Remove mounting bolts of intake manifold. (The joint of intake manifold and rocker cover.)

10. Loosen mounting bolts in reverse order as shown in the figure.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

11. Remove intake manifold.

12. Remove EVAP canister purge volume control solenoid valve from intake manifold if necessary.

CAUTION:

Never impact it.

13. Remove intake manifold support (1) if necessary.

CAUTION:

The intake manifold support functions as a guide for install-
ing the intake manifold.

INSTALLATION

Note the following, and install in the reverse order of removal.

Intake Manifold

1.

Install the gasket to the intake manifold.
• Align the protrusions used for checking gasket installation con-

dition with the clearance grooves (A) of the intake manifold
mounting groove.

NOTE:
Gasket for electronically-controlled throttle can be installed
when the electronically-controlled throttle is installed.

2.

Place the intake manifold into the installation position.

CAUTION:

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INTAKE MANIFOLD

EM-165

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Check that the oil level gauge guide is not detached from the securing clip of the water inlet due to
interference of intake manifold.

3.

Tighten bolts in the numerical order as shown in the figure.

4.

Tighten mounting bolts of intake manifold. (The joint of intake manifold and rocker cover.)

Electric Throttle Control Actuator

• Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
• Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the elec-

tric throttle control actuator. Refer to

EC-543, "Description"

.

• Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing

electric throttle control actuator. Refer to

EC-544, "Description"

JPBIA4124ZZ

EM-166

< REMOVAL AND INSTALLATION >

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EXHAUST MANIFOLD

EXHAUST MANIFOLD

Exploded View

INFOID:0000000006449902

Removal and Installation

INFOID:0000000006449903

REMOVAL

1.

Remove exhaust front tube. Refer to

EX-12, "Exploded View"

.

2.

Remove air duct. Refer to

EM-161, "Exploded View"

.

3.

Remove the harness bracket fixing the harness connector of the air-fuel ratio sensor from the cylinder
head on the rear right side.

JPBIA4091GB

1.

Exhaust manifold cover

2.

Harness bracket

3.

Air fuel ratio sensor 1

4.

Exhaust manifold stay

5.

Heat insulator

6.

Exhaust manifold

7.

Exhaust manifold cover

8.

Gasket

: Engine front

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

EXHAUST MANIFOLD

EM-167

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4.

Remove exhaust manifold cover.

5.

Remove the air fuel ratio sensor 1.
• Using heated oxygen sensor wrench [SST: KV10117100] (A),

remove air fuel ratio sensor 1.

CAUTION:

• If O2 sensor is dropped on to a hard surface like a con-

crete floor from a height of 0.5 m or more, discard the
sensor and use a new one.

• Clean the mounting area of O2 sensor before installing a

new O2 sensor.

NOTE:
The exhaust manifold can be removed and installed without
removing the air fuel ratio sensor 1 (Disassembly of harness
connector is necessary).

6.

Remove exhaust manifold side mounting bolt of exhaust manifold stay.

7.

Remove the harness bracket of air fuel ratio sensor 1 from cylinder head.

8.

Remove exhaust manifold.
• Loosen nuts in reverse order as shown in the figure.

9.

Remove stud bolt from cylinder head.
• Using TORX socket.

10. Remove exhaust manifold cover from exhaust manifold back side.

INSTALLATION

NOte the following, and install in the reverse order of removal.

Exhaust manifold

1.

Tighten nuts in numerical order as shown in the figure.

2.

Tighten to the specified torque again.

Inspection

INFOID:0000000006449904

INSPECTION AFTER REMOVAL

Surface Distortion

JPBIA4126ZZ

JPBIA4127ZZ

JPBIA4127ZZ

EM-168

< REMOVAL AND INSTALLATION >

[HR16DE]

EXHAUST MANIFOLD

• Using feeler gauge (A) and straightedge (B), check the surface dis-

tortion of exhaust manifold mating surface in each exhaust port
and entire part.

• If it exceeds the limit, replace exhaust manifold.

Limit

: Refer to

EM-251, "Exhaust Manifold"

.

PBIC3530J

OIL PAN (LOWER)

EM-169

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OIL PAN (LOWER)

Exploded View

INFOID:0000000006449905

With Oil Cooler

JPBIA4743GB

1.

Rear oil seal

2.

O-ring

3.

Oil pan (upper)

4.

Oil pump chain tensioner (for oil
pump drive chain)

5.

Oil pump drive chain

6.

Crankshaft sprocket

7.

Oil pump sprocket

8.

Oil pump

9.

O-ring

10. O-ring

11.

Oil pan (lower)

12. Oil pan drain plug

13. Drain plug washer

14. Oil level sensor

15. Relief valve

16. Connector bolt

17. Oil filter

18. Oil cooler

19. O-ring

A.

Refer to

EM-182

B.

Refer to

LU-28

C.

Oil pan (lower) side

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Sealing point

: Should be lubricated with oil.

EM-170

< REMOVAL AND INSTALLATION >

[HR16DE]

OIL PAN (LOWER)

With Out Oil Cooler

Removal and Installation

INFOID:0000000006449906

REMOVAL

1.

Drain engine oil. Refer to

CO-11, "Draining"

.

2.

Remove oil pan (lower) with the following procedure:

JPBIA4742GB

1.

Rear oil seal

2.

O-ring

3.

Oil pan (upper)

4.

Oil pump chain tensioner (for oil
pump drive chain)

5.

Oil pump drive chain

6.

Crankshaft sprocket

7.

Oil pump sprocket

8.

Oil pump

9.

O-ring

10. O-ring

11.

Oil pan (lower)

12. Oil pan drain plug

13. Drain plug washer

14. Oil level sensor

15. Oil filter stud bolt

16. Oil filter

A.

Refer to

EM-182

B.

Refer to

LU-28

C.

Oil pan (lower) side

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Sealing point

: Should be lubricated with oil.

OIL PAN (LOWER)

EM-171

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a.

Loosen mounting bolts in reverse order as shown in the figure.

b.

Insert seal cutter [SST: KV10111100] (A) between oil pan (upper)
and oil pan (lower).

CAUTION:

• Be careful not to damage the mating surface.
• Never insert a screwdriver. This damages the mating sur-

faces.

c.

Slide the seal cutter [SST: KV10111100] by tapping on the side
of tool with a hammer.

d.

Remove oil pan (lower).

INSTALLATION

1.

Install oil pan (lower) as follows:

a.

Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Also remove old liquid gasket from mating surface of oil pan

(upper).

• Remove old liquid gasket from the bolt holes and threads.

CAUTION:

Never scratch or damage the mating surface when cleaning
off old liquid gasket.

: Engine front

JPBIA4744ZZ

JPBIA0276ZZ

JPBIA4745ZZ