Nissan Juke (2012 year). Service Repair Manual — part 109
EM-26
< REMOVAL AND INSTALLATION >
[MR16DDT ]
AIR CLEANER AND AIR DUCT
7.
Remove air cleaner cover assembly.
8.
Remove mass air flow sensor from air cleaner cover, 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.
9.
Remove air duct inlet (lower) with the following procedure.
a.
Remove fender protector (LH). Refer to
.
b.
Remove air duct inlet (lower).
INSTALLATION
Note the following, and install in the reverse order of removal.
• Align marks. Attach each joint. Screw clamps firmly.
• Fixing clips shall be fixed after inserting air cleaner body assembly protrusion to air cleaner case botch hole.
• Make sure whether air cleaner body has been firmly installed by shaking it.
Inspection
INFOID:0000000007577432
INSPECTION AFTER REMOVAL
Inspect air duct and resonator assembly for crack or tear.
• If anything found, replace air duct and resonator assembly.
Revision: 2011 October
2012 JUKE
INTAKE MANIFOLD
EM-27
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INTAKE MANIFOLD
Exploded View
INFOID:0000000007577433
1.
Clamp
2.
Water hose
3.
PCV hose
4.
Gasket
5.
Intake manifold
6.
Vacuum tube
7.
Vacuum hose (with check valve)
8.
Vacuum hose
9.
Vacuum gallery assembly
10. EVAP hose
11.
EVAP check valve
12. EVAP hose
13.
EVAP canister purge volume control
solenoid valve
14. Bracket
15. Bracket
16. EVAP hose
17. EVAP service port
18. EVAP hose
19. EVAP tube
20. EVAP hose
21. Water hose
22. Electric throttle control actuator
23. Gasket
A.
To turbocharger
B.
To centralized under-floor piping
C.
To recirculation valve hose
D.
To break booster hose
: N·m (kg-m, ft-lb)
JPBIA4874GB
Revision: 2011 October
2012 JUKE
EM-28
< REMOVAL AND INSTALLATION >
[MR16DDT ]
INTAKE MANIFOLD
Removal and Installation
INFOID:0000000007577434
REMOVAL
1.
Remove engine cover. Refer to
2.
Pull out oil level gauge.
CAUTION:
Cover the oil level gauge guide openings to avoid entry of foreign materials.
3.
Disconnect turbocharger boost sensor (with intake air temperature sensor 2) harness connector. Refer to
4.
Remove air inlet tube assembly. Refer to
.
5.
Disconnect water hoses from electric throttle control actuator as follows:
• Attach plug to prevent engine coolant leakage when engine coolant is not drained. Refer to
.
CAUTION:
Perform this step when the engine is cold.
NOTE:
This step is not required when removing only intake manifold.
6.
Disconnect electric throttle control actuator harness connector.
7.
Remove electric throttle control actuator.
CAUTION:
• Handle carefully to avoid any shock to electric throttle control actuator.
• Never disassemble electric throttle control actuator.
8.
Remove EVAP vacuum tank.
9.
Disconnect EVAP canister purge volume control solenoid valve harness connector, and them remove
bracket with EVAP canister purge volume control solenoid valve.
10. Remove vacuum gallery.
11. Disconnect PCV hose (intake manifold side).
12. Remove intake manifold (1) with the following procedure.
• Loosen and remove intake manifold mounting bolt (A).
• Loosen mounting bolts in reverse order as shown in the figure.
NOTE:
Disregard the numerical order No.6 in removal.
CAUTION:
Cover engine openings to avoid entry of foreign materi-
als.
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
,
,
: Indicates that the part is connected at points with same symbols in actual vehicle.
JPBIA4385ZZ
: Engine front
JPBIA4356ZZ
Revision: 2011 October
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INTAKE MANIFOLD
EM-29
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INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold
1.
Check if gasket is not dropped from the installation groove of intake manifold.
2.
Install intake manifold with the following procedure:
a.
Tighten in numerical order as shown in the figure.
NOTE:
• Tighten bolt the No.1 in two steps.
• The numerical order No.6 shows the second step.
3.
Install in the reverse order of removal after this step.
CAUTION:
Since check valve is built-in inside vacuum hose (1), install
the vacuum hose fitting the arrow (A) to intake manifold
side (2).
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
.
• Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing
electric throttle control actuator. Refer to
.
Inspection
INFOID:0000000007577435
INSPECTION AFTER REMOVAL
Vacuum hose (with check valve)
Check that the check valve. Refer to
: Engine front
JPBIA4356ZZ
JPBIA4441ZZ
Revision: 2011 October
2012 JUKE
EM-30
< REMOVAL AND INSTALLATION >
[MR16DDT ]
CHARGE AIR COOLER
CHARGE AIR COOLER
Exploded View
INFOID:0000000007577436
Removal and Installation
INFOID:0000000007577437
REMOVAL
Air inlet hose 1, Air inlet tube 1 and Recirculation valve
1.
Remove engine cover. Refer to
1.
Air inlet tube 3
2.
Mounting rubber (gray)
3.
Air inlet tube bracket
4.
Clamp
5.
Air inlet hose 2
6.
Gasket
7.
Turbocharger
8.
Mounting rubber
9.
Charge air cooler
10. Air inlet tube 2
11.
Air inlet tube bracket
12. Air inlet hose 1
13. Air inlet tube 1
14. O-ring
15. Turbocharger boost sensor
16. Grommet
17. Mounting rubber (black)
18. Air inlet hose
19. Clamp
20. Recirculation valve
21. Clamp
22. Vacuum hose
A.
To vacuum gallery assembly
B.
To electric throttle control actuator
C.
To turbocharger
: Vehicle front
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
: Should be lubricated with oil.
JPBIA5704GB
Revision: 2011 October
2012 JUKE
CHARGE AIR COOLER
EM-31
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2.
Make matching marks on each connecting part for reference at installation.
3.
Remove recirculation hose and vacuum hose to recirculation valve.
4.
Loosen clamp, and then remove air inlet hose 1.
5.
Remove recirculation valve and turbocharger boost sensor from air inlet tube 1, if necessary.
6.
loosen clamp, and then remove air inlet hose 1.
Air inlet tube 3
1.
Remove engine cover. Refer to
.
2.
Make matching marks on each connecting part for reference at installation.
3.
Loosen clamp, and then remove air inlet tube 3.
Charge air cooler, Air inlet hose 2 and Air inlet tube 2
1.
Remove front bumper. Refer to
.
2.
Remove radiator core support upper. Refer to
(With intelligent key system) or
(Without intelligent key system).
3.
Make matching marks on each connecting part for reference at installation.
4.
Remove air inlet hose 2.
5.
Loosen air inlet tube 2 clamp, and then remove charge air cooler
(1).
CAUTION:
• Avoid interference between the charge air cooler and radi-
ator.
• When removing charge air cooler, close opening on turbo
charger and intake manifold with shop cloth or other suit-
able material.
6.
Remove air inlet tube 2, if necessary.
INSTALLATION
Install in the reverse order of removal paying attention to the following points:
CAUTION:
Do not reuse O-rings.
• Apply a neutral detergent (fluid) to the joint between hoses and pipes (oil is not permissible).
• Pay attention to identification mark and direction.
Inspection
INFOID:0000000007577438
INSPECTION AFTER REMOVAL
1.
Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it
dry.
2.
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler in necessary.
• Be careful not to deform core fins.
• For cleaning procedure of charge air cooler core, refer to
.
JPBIA4357ZZ
Revision: 2011 October
2012 JUKE
EM-32
< REMOVAL AND INSTALLATION >
[MR16DDT ]
CATALYST
CATALYST
2WD
2WD : Exploded View
INFOID:0000000007577439
2WD : Removal and Installation
INFOID:0000000007577440
REMOVAL
1.
Remove engine cover. Refer to
2.
Remove cowl top extension. Refer to
3.
Remove front tube. Refer to
.
4.
Remove catalyst converter support bracket (lower).
5.
Remove A/F sensor 1.
• Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], remove A/F sensor 1.
CAUTION:
• Never damage air fuel ratio sensor 1.
• Discard any sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a
hard surface such as a concrete floor; use a new one.
JPBIA4321GB
1.
A/F sensor 1
2.
Catalyst converter shroud upper
3.
Gasket
4.
Catalyst converter
5.
Catalyst converter support bracket
(lower)
6.
Catalyst converter support bracket
(upper)
A.
To exhaust system
Engine front
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
,
: Indicates that the parts is connected at points with same symbols in actual vehicle.
Revision: 2011 October
2012 JUKE
CATALYST
EM-33
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6.
Remove catalyst converter shroud upper.
7.
Remove bolts and nut of catalyst converter turbocharger side.
8.
Remove catalyst converter support bracket (upper).
9.
Remove heat insulator. Refer to
10. Remove catalyst converter.
11. Remove gasket.
INSTALLATION
1.
Install gasket between turbocharger and catalyst as shown in
the figure.
2.
Install catalyst converter with the following procedure.
• Tighten in numerical order as shown in the figure.
- Install catalyst converter (base on stud position 1).
- Temporary assemble 2 (no priority).
- Temporary assemble 3, 4.
- Tightening 5, 6 and 7.
- Tightening again 8, 9 and 10.
- Temporary assemble 11.
- Tightening 12,13,14,and 15.
3.
Note the following, and install in the reverse order of removal.
A/F sensor 1
• Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], install A/F sensor 1.
CAUTION:
• Before installing a new sensors, clean exhaust system threads using heated oxygen sensor
thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply anti-seize
lubricant.
• Never apply excessive torque to sensor 2. Doing so may cause damage to sensor 2, resulting
in the “MIL” illuminating.
• Prevent rust preventives from adhering to the sensor body.
AWD
1
: Gasket
A
: Turbocharger side
B
: Catalyst converter side
C
: Claw
JPBIA4418ZZ
JPBIA4362GB
Revision: 2011 October
2012 JUKE
EM-34
< REMOVAL AND INSTALLATION >
[MR16DDT ]
CATALYST
AWD : Exploded View
INFOID:0000000007577441
AWD : Removal and Installation
INFOID:0000000007577442
REMOVAL
1.
Drain engine coolant. Refer to
2.
Remove engine cover. Refer to
3.
Remove cowl top extension. Refer to
4.
Remove front tube. Refer to
5.
Remove catalyst converter support bracket (lower).
6.
Remove A/F sensor 1 and heated oxygen sensor 2.
• Use heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], remove A/F sensor 1 and heated
oxygen sensor 2.
CAUTION:
• Never damage air fuel ratio sensor 1 and heated oxygen sensor 2.
• Discard any sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a
hard surface such as a concrete floor; use a new one.
JPBIA4345GB
1.
A/F sensor 1
2.
Catalyst converter shroud upper
3.
Gasket
4.
Heated oxygen sensor 2
5.
Catalyst converter support bracket
(lower)
6.
Catalyst converter
7.
Catalyst converter support bracket
(upper)
A.
To exhaust system
Engine front
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
,
: Indicates that the parts is connected at points with same symbols in actual vehicle.
Revision: 2011 October
2012 JUKE
CATALYST
EM-35
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7.
Remove catalyst converter shroud (upper).
8.
Remove bolts and nut of catalyst converter turbocharger side.
9.
Remove heat insulator. Refer to
10. Remove catalyst converter support bracket (upper).
11. Remove catalyst converter. And keep a service area.
NOTE:
Slide the catalyst converter in a lateral direction to obtain work space for removing turbocharger.
12. Remove turbocharger. Refer to
13. Pull up and remove catalyst converter.
14. Remove gasket.
INSTALLATION
1.
Install gasket between turbocharger and catalyst as shown in
the figure.
2.
Install catalyst converter with the following procedure.
• Tighten in numerical order as shown in the figure.
- Install catalyst converter (base on stud position 1).
- Temporary assemble 2 (no priority).
- Temporary assemble 3, 4.
- Tightening 5, 6 and 7.
- Tightening again 8, 9 and 10.
- Temporary assemble 11.
- Tightening 12,13,14,and 15.
3.
Note the following, and install in the reverse order of removal.
A/F sensor 1 and Heated oxygen sensor 2
• Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], install A/F sensor 1 and heated
oxygen sensor 2.
CAUTION:
• Before installing a new sensors, clean exhaust system threads using heated oxygen sensor
thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply anti-seize
lubricant.
• Never apply excessive torque to sensors. Doing so may cause damage to sensors, resulting in
the “MIL” illuminating.
1
: Gasket
A
: Turbocharger side
B
: Catalyst converter side
C
: Claw
JPBIA4418ZZ
JPBIA4371GB
Revision: 2011 October
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EM-36
< REMOVAL AND INSTALLATION >
[MR16DDT ]
CATALYST
• Prevent rust preventives from adhering to the sensor body.
Revision: 2011 October
2012 JUKE
TURBOCHARGER
EM-37
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TURBOCHARGER
Exploded View
INFOID:0000000007577443
Removal and Installation
INFOID:0000000007577444
REMOVAL
1.
Heat insulator
2.
Actuator hose
3.
Clamp
4.
Turbocharger inlet tube
5.
Gasket
6.
Gasket
7.
Clamp
8.
Oil outlet hose
9.
Oil return pipe
10. Oil supply tube
11.
O-ring
12. Gasket
13. Turbocharger
14. Eye bolt
15. Gasket
16. Oil supply tube
A.
To boost control solenoid valve
B.
To air inlet hose
C.
To PCV hose
D.
To air duct
E.
To air inlet tube assembly
F.
To catalyst converter
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
JSBIA1974GB
Revision: 2011 October
2012 JUKE
EM-38
< REMOVAL AND INSTALLATION >
[MR16DDT ]
TURBOCHARGER
1.
Drain engine coolant. Refer to
2.
Remove engine cover. Refer to
3.
Remove air cleaner cover assembly and air cleaner body assembly. Refer to
.
4.
Remove air inlet tube 3. Refer to
.
5.
Remove cowl top extension. Refer to
6.
Disconnect heated oxygen sensor 2 harness connector.
7.
Remove front tube. Refer to
.
8.
Remove catalyst converter. Refer to
(AWD models).
9.
Remove turbocharger assembly as follows:
a.
Remove heat insulator.
b.
Disconnect water hose from turbocharger. Refer to
c.
Remove oil supply tube.
d.
Remove mounting nuts of turbocharger.
CAUTION:
Never deform each turbocharger piping when pulling out the assembly.
INSTALLATION
CAUTION:
Do not reuse O-rings.
Install in the reverse order of removal.
Inspection
INFOID:0000000007577445
INSPECTION PROCERDURE
Trouble Diagnosis of Turbocharger
Check items before trouble diagnosis
1.
Check that the engine oil level is between L (Low level) and H (High level) of the oil level gauge. [When
the engine oil amount is more then H (High level), the engine oil flows into the inlet duct through the blow-
by gas passage, and the turbocharger is misjudged failure.]
2.
Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.
• Replace the exhaust manifold and turbocharger assembly when any malfunction is found after unit
inspections specified in the table below.
• If no malfunction is found after the unit inspections, judge that the turbocharger body has no non-stan-
dard conditions. Check the other parts again.
Inspection Location
Result
Symptoms likely to occur when the results shown on
the left exist.
Oil leakage
Smoke
Noise
Poor pow-
er
Poor ac-
celeration
Turbine wheel
Wet with oil.
C
A
C
C
Carbon deposits observed.
C
A
B
B
“Rubs against” housing.
C
B
A
B
Vane is bent or broken.
A
A
Compressor wheel
Inside of intake port is badly stained
with oil.
B
B
“Rubs against” housing.
C
B
A
B
Vane is bent or broken.
A
A
Revision: 2011 October
2012 JUKE
TURBOCHARGER
EM-39
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INSPECTION AFTER REMOVAL
Turbocharger
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:
Turbocharger Boost Control
Check both turbine and compres-
sor rotor shaft end play.
Heavy feel or catching when turned by
hand.
C
C
B
Cannot be turned by hand.
A
Excessively loose bearing.
C
C
B
C
Rotor shaft, oil return port (Check
inside using penlight.)
Carbon or sludge deposits in oil drain
port.
C
A
C
C
Boost control valve actuator oper-
ation (using a handy pump)
• Does not operate smoothly when air
pressure is gradually applied.
• Stroke amount is not compliance
with the air pressure.
A
A:
Highly possible.
B:
Possible.
C:
May exist.
Inspection Location
Result
Symptoms likely to occur when the results shown on
the left exist.
Oil leakage
Smoke
Noise
Poor pow-
er
Poor ac-
celeration
JPBIA4359ZZ
A.
Check for leakage
Suction side
: Between turbocharger and charge air cooler
Exhaust side
: Between turbocharger and outlet duct
Revision: 2011 October
2012 JUKE
EM-40
< REMOVAL AND INSTALLATION >
[MR16DDT ]
TURBOCHARGER
• Connect the a pressurized handy pump (A) to the actuator, and
check that the rod strokes smoothly in compliance with the follow-
ing pressure.
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.
Standard (value of pressure/Value of rod moving):
JPBIA0665ZZ
Revision: 2011 October
2012 JUKE
EXHAUST MANIFOLD
EM-41
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EXHAUST MANIFOLD
Exploded View
INFOID:0000000007577446
Removal and Installation
INFOID:0000000007577447
REMOVAL
1.
Drain engine coolant. Refer to
2.
Remove front tube. Refer to
.
3.
Remove turbocharger. Refer to
4.
Remove exhaust manifold cover.
5.
Remove exhaust manifold.
JSBIA1975GB
1.
Stud bolt
2.
Exhaust manifold cover
3.
Exhaust manifold
4.
Gasket
Engine front
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
Revision: 2011 October
2012 JUKE
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