Nissan Juke (2012 year). Service Repair Manual — part 110
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< REMOVAL AND INSTALLATION >
[MR16DDT ]
EXHAUST MANIFOLD
• Loosen nuts in reverse order as shown in the figure.
NOTE:
Disregard the numerical order No. 9 to 12 in removal.
6.
Remove gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION
1.
Install gasket to cylinder head as shown in the figure.
2.
Install exhaust manifold with the following procedure:
a.
Tighten nuts in numerical order as shown in the figure.
NOTE:
• Tighten nuts the No.1 to No.4 in two steps.
• The numerical order No.9 to No.12 shows the second step.
3.
Install remaining parts in the reverse order of removal.
Inspection
INFOID:0000000007577448
INSPECTION AFTER REMOVAL
Surface Distortion
• 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.
: Engine front
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: Engine front
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: Engine front
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Limit
: Refer to
.
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OIL PAN (LOWER)
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OIL PAN (LOWER)
Exploded View
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1.
O-ring
2.
Oil pan (upper)
3.
Oil level gauge guide
4.
O-ring
5.
Oil level gauge
6.
Oil pump drive chain
7.
Crankshaft sprocket
8.
Oil pump sprocket
9.
Oil pump chain tensioner
10. Oil pump
11.
Drain plug
12. Drain plug washer
13. Oil pan (lower)
14. Oil filter
15. Connector bolt
16. Clamp
17. Water hose
18. Oil cooler
19. Crankshaft position sensor
20. Gasket
21. Oil pan bolt
22. Rear oil seal
A.
B.
To thermostat hosing
C.
To thermostat housing (M/T models)
To CVT oil warmer (CVT models)
D.
Oil pan side
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
: Sealing point
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EM-44
< REMOVAL AND INSTALLATION >
[MR16DDT ]
OIL PAN (LOWER)
Removal and Installation
INFOID:0000000007577450
REMOVAL
1.
Drain engine oil. Refer to
.
2.
Remove oil pan (lower) with the following procedure:
a.
Loosen mounting bolts in reverse order as shown in the figure.
NOTE:
Disregard the numerical order No.7 and No.11 in removal.
b.
Insert seal cutter [SST: KV10111100 (J-37228)] (A) between oil
pan (upper) and oil pan (lower).
CAUTION:
• Never damage the mating surface.
• Never insert a screwdriver. This damages the mating sur-
faces.
c.
Slide the seal cutter [SST: KV10111100 (J-37228)] by tapping on
the side of tool with a hammer.
d.
Remove oil pan (lower).
INSTALLATION
CAUTION:
Do not reuse drain plug washer.
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.
: Should be lubricated with oil.
: Indicates that the parts is connected at points with same symbols in actual vehicle.
: Engine front
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OIL PAN (LOWER)
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b.
Apply a continuous bead of liquid gasket (A) with a tube presser
(commercial service tool) as shown in the figure.
Use Genuine RTV Silicon Sealant or equivalent. Refer to
22, "Recommended Chemical Products and Sealants"
.
CAUTION:
Attaching should be done within 5 minutes after liquid gas-
ket application.
c.
Tighten bolts in numerical order as shown in the figure.
NOTE:
• Tighten bolts the No.1 and No.2 in two steps.
• The numerical order No.7 and No.11 shows the second steps.
2.
Install oil pan drain plug.
CAUTION:
Do not reuse drain plug washer.
• Refer to the figure of components of former page for installation direction of drain plug washer. Refer to
.
3.
Install in the reverse order of removal after this step.
Inspection
INFOID:0000000007577451
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSPECTION AFTER INSTALLATION
1.
Check the engine oil level and adjust engine oil. Refer to
2.
Start engine, and check there is no leakage of engine oil.
3.
Stop engine and wait for 10 minutes.
4.
Check the engine oil level again. Refer to
.
1
: Oil pan (lower)
b
: 7.5 - 9.5 mm (0.295 - 0.374 in)
c
:
φ
4.0 - 5.0 mm (0.157 - 0.197 in)
: Engine outside
: Engine front
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: Engine front
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EM-46
< REMOVAL AND INSTALLATION >
[MR16DDT ]
HIGH PRESSURE FUEL PUMP AND FUEL HOSE
HIGH PRESSURE FUEL PUMP AND FUEL HOSE
Exploded View
INFOID:0000000007577452
CAUTION:
Never remove or disassemble parts unless instructed as shown in the figure.
Removal and Installation
INFOID:0000000007577453
REMOVAL
WARNING:
EM-5, "Precaution for Handling High Pressure Fuel System"
when working on the
high pressure fuel system.
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO
2
fire extinguisher.
1.
High pressure fuel pump insulator
2.
High pressure fuel pump
3.
O-ring
4.
High pressure fuel pump lifter
5.
Fuel rail connector
6.
Fuel tube
7.
Bracket
8.
Fuel pump connector protector
9.
Fuel feed hose
A.
To centralized under-floor piping
: Engine front
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
: Should be lubricated with oil.
: Indicates that the parts is connected at points with same symbols in actual vehicle.
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HIGH PRESSURE FUEL PUMP AND FUEL HOSE
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• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
• To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1.
Release fuel pressure. Refer to
2.
Remove engine cover. Refer to
.
3.
Remove fuel pump connector protector, and remove high pressure fuel pump insulator.
4.
Disconnect quick connector (A) with the following procedure.
a.
Disconnect fuel feed hose (1) from bracket hose clamp (2).
b.
Disengage (A) and pull up (B) the pawl of the fuel feed hose
connector retainer (C) to disconnect the fuel feed hose from high
pressure fuel pump.
NOTE:
If the fuel feed hose is stuck, hold the fuel pipe by hand and dis-
connect it by pushing and pulling.
CAUTION:
• Keep parts away from heat source. Especially, be careful
when welding is performed around them.
• Never expose parts to battery electrolyte or other acids.
• Never bent or twist connection between quick connector
and fuel feed hose (with damper) during installation/
removal.
• Pull quick connector holding (D).
• Never remove the retainer.
• Prepare a tray and waste beforehand as fuel leaks out.
• Never pull with lateral force applied. O-ring inside quick
connector may be damaged.
• To prevent damage to each joint and protect it from the
entry of foreign matter, cover the joint with plastic bag (A)
or an equivalent.
5.
Remove intake manifold. Refer to
EM-28, "Removal and Installation"
6.
Remove fuel tube.
7.
Remove fuel rail connector.
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Retainer color
: Red
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EM-48
< REMOVAL AND INSTALLATION >
[MR16DDT ]
HIGH PRESSURE FUEL PUMP AND FUEL HOSE
8.
Remove high pressure fuel pump (1) and lifter.
CAUTION:
To prevent damage to high pressure fuel pump and cam-
shaft bracket, loosen bolt (A) alternately by one turn at a
time until the reaction force applied on the high pressure
fuel pump disappears.
INSTALLATION
CAUTION:
• Do not reuse O-rings.
• To prevent damage to parts due to generated abnormal stress and eccentric load, always observe
the installation procedure.
1.
Install high pressure fuel pump according to the following procedure.
a.
Check the orientation of pump cam from the mounting area
(view arrow) of high pressure fuel pump.
b.
Aim pump cam at the BDC area (arrow position).
NOTE:
For BDC area, anywhere within the area indicated by arrow can
be accepted.
c.
Install O-ring to high pressure fuel pump. When handing new O-ring, paying attention to the following cau-
tion items:
CAUTION:
• Do not reuse O-ring.
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• Never damage O-ring with tools and fingernails during the installation. In addition, twisting or
stretching O-ring is not allowed. If O-ring is stretched during the installation to high pressure
fuel pump, never install high pressure fuel pump immediately.
d.
Install high pressure fuel pump lifter.
e.
Apply oil to the fitting area of high pressure fuel pump O-ring and camshaft bracket side to install high
pressure fuel pump.
f.
Install high pressure fuel pump. To prevent damage to high pressure fuel pump and camshaft bracket, the
following instructions must be observed.
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: Camshaft (EXH)
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HIGH PRESSURE FUEL PUMP AND FUEL HOSE
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CAUTION:
• Temporarily tighten bolt (A) by hand. Alternately tighten
bolt by one turn at a time until high pressure fuel pump
reaches camshaft bracket.
• After a pump flange sitting, tighten the bolts to the speci-
fied torque.
2.
Connect fuel feed hose with the following procedure, and them install the fuel feed hose.
a.
Check no foreign substances are deposited in and around matching pipe and quick connector, and no
damage on them.
b.
Quick connector shall be inserted gradually, aligning with the axis of the matching pipe.
c.
Insert the retainer until it clicks and check the retainer is locked.
After insertion, pull the connector and check that the connector
is locked.
CAUTION:
If retainer cannot be installed smoothly, quick connector
may be have not been installed correctly. Check connection
again.
d.
After attaching the quick connector and fix the hose to the clamp.
3.
Install new fuel rail connector (1).
CAUTION:
• Never reuse fuel rail connector.
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign
material.
• Never scratch O-ring with tools or fingernails when
installing fuel rail connector.
• Insert new fuel rail connector straight into fuel rail. Never decenter or twist the fuel rail connec-
tor during insertion.
4.
Install the fuel tube with the following procedure.
CAUTION:
• When removing fuel tube, always replace fuel rail connector together with fuel tube.
• Never reuse fuel tube.
• Never use fuel tube if its terminal tip is damaged.
• Observe the tightening order and the tightening torque.
1
: High pressure fuel pump
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A
: Lock position
B
: Unlock position
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2
: O-ring
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EM-50
< REMOVAL AND INSTALLATION >
[MR16DDT ]
HIGH PRESSURE FUEL PUMP AND FUEL HOSE
a.
Temporarily tighten flare nut (A) and (B) of fuel tube (3) until
seated.
CAUTION:
When temporarily tightening flare nut, place pipe in the cen-
ter of the nut inner diameter.
b.
Temporarily tighten bolt (4) until the seat of bracket is seated.
c.
Tighten flare nut (A) and (B) in alphabetical order.
CAUTION:
Always fit the tool completely with the nut.
d.
Tighten bolt (4).
5.
Install in the reverse order of removal after this step.
Inspection
INFOID:0000000007577454
INSPECTION AFTER INSTALLATION
Check for Fuel Leakage
1.
Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check that
there is no fuel leakage at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.
2.
Start the engine. With engine speed increased, check again that there is no fuel leakage at connection
points.
CAUTION:
Never touch the engine immediately after it is stopped because the engine is extremely hot.
1
: High pressure fuel pump
2
: Fuel rail connector
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FUEL INJECTOR AND FUEL TUBE
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FUEL INJECTOR AND FUEL TUBE
Exploded View
INFOID:0000000007577455
CAUTION:
• Never remove or disassemble parts unless instructed as shown in the figure.
• When fuel rail insulator (separated type) and adaptor cover (separated type) are removed, be sure to
replace them with fuel insulator (united type).
Removal and Installation
INFOID:0000000007577456
WARNING:
1.
Holder
2.
Seal ring (white)
3.
Backup ring
4.
O-ring (blue)
5.
Fuel injector
6.
Stud bolt
7.
Fuel rail
8.
Fuel rail insulator (united type)
9.
Adaptor cover (separated type)
10. Fuel rail insulator (separated type)
11. Fuel rail cover
12. Fuel pressure sensor
13. Gasket
A.
To fuel rail connector and fuel tube.
Refer to
B.
Comply with the assembly procedure
when tightening. Refer to
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
: Should be lubricated with oil.
: Indicates that the parts is connected at points with same symbols in actual vehicle.
JSBIA1675GB
Revision: 2011 October
2012 JUKE
EM-52
< REMOVAL AND INSTALLATION >
[MR16DDT ]
FUEL INJECTOR AND FUEL TUBE
EM-5, "Precaution for Handling High Pressure Fuel System"
when working on the
high pressure fuel system.
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO
2
fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
• To avoid the danger of being scalded, never drain engine coolant when engine is hot.
REMOVAL
1.
Release the fuel pressure. Refer to
.
2.
Remove front bumper. Refer to
3.
Remove charge air cooler. Refer to
4.
Remove oil level gauge. Refer to
5.
Remove intake manifold. Refer to
6.
Remove alternator. Refer to
7.
Remove oil level gauge guide. Refer to
8.
Remove fuel rail cover, and then remove fuel rail insulator.
CAUTION:
When fuel rail insulator (separated type) and adapter cover (separated type) are removed, be sure
to replace them with fuel rail insulator (united type).
9.
Remove fuel tube and fuel rail connector. Refer to
10. Disconnect fuel pressure sensor harness connector.
11. Disconnect fuel injector harness connector.
12. Remove fuel pressure sensor, if necessary.
13. Remove fuel rail.
• Loosen mounting bolts in reverse order as shown in the figure.
CAUTION:
• When removing, be careful to avoid any interference with fuel
injector.
• Use a shop cloth to absorb any fuel leakage from fuel rail.
14. Remove fuel injector from cylinder head as per the following.
CAUTION:
• Be careful with remaining fuel that may go out from fuel rail.
• Be careful not to damage injector nozzles during removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector.
a.
Remove injector holder.
b.
Install an remover [SST: KV10119600 (—)] (A) to the injector
connector side so that cutout (B) of injector remover faces the
injector connector side.
: Engine front
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FUEL INJECTOR AND FUEL TUBE
EM-53
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• Hook pawl portion (B) of injector remover [SST: KV10119600
(—)] (A) to groove portion (C) of injector
c.
Press down body portion of injector remover [SST: KV10119600
(—)] (A) until it contacts cylinder head.
d.
Tighten injector remover [SST: KV10119600 (—)] clockwise and
remove injector from cylinder head.
e.
Cut seal ring (1) while pinching it. Be careful not to damage
injector.
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EM-54
< REMOVAL AND INSTALLATION >
[MR16DDT ]
FUEL INJECTOR AND FUEL TUBE
INSTALLATION
CAUTION:
Do not reuse O-rings.
1.
Install seal ring to fuel injector as per the following:
CAUTION:
• Handle seal ring with bare hands. Never wear gloves.
• Never apply engine oil to seal ring.
• Never clean seal ring with solvent.
a.
Install an injector seal drift set [SST: KV101197S0 (—)] (A) to
fuel injector (1).
b.
Set seal ring (1) to injector seal drift set [SST: KV101197S0 (—)]
(A).
c.
Straightly insert seal ring (1), which is set in step 2, to fuel injec-
tor as shown in the figure and install.
CAUTION:
Be careful that seal ring does not exceed the groove portion
of fuel injector.
d.
Insert injector seal drift set [SST: KV101197S0 (—)] (A) to injec-
tor and rotate clockwise and counterclockwise by 90
°
while
pressing seal ring to fit it.
NOTE:
Compress seal ring, because this operation is for rectifying
stretch of seal ring caused by installation and for preventing
sticking when inserting injector into cylinder head.
2.
Install O-ring and backup ring to fuel injector. When handing new O-ring and backup ring, paying attention
to the following caution items:
CAUTION:
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Revision: 2011 October
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FUEL INJECTOR AND FUEL TUBE
EM-55
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• Do not reuse O-ring.
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly
into fuel tube.
• Insert new O-ring straight into fuel rail. Never decenter or twist it.
• Always install the back up ring (1) in the right direction as
instructed.
3.
Install fuel injector (1) to fuel rail (2) as per the following:
a.
Install fuel injector holder (5) to fuel injector.
CAUTION:
• Never reuse fuel injector holder. Replace it with a new
one.
• Be careful to keep fuel injector holder from interfering
with O-ring. If interference occurs, replace O-ring.
b.
Insert fuel injector into fuel rail with fuel injector holder attached.
• Insert it while matching it to the axial center.
• Insert so that protrusion (A) of fuel injector is aligned to cutout
(B).
c.
Check that installation is complete by checking that fuel injector
does not rotate or come off.
• Check that protrusions of fuel injectors and fuel rail are aligned
with cutouts of clips after installation.
4.
Install fuel rail and fuel injector assembly to cylinder head.
• Tighten mounting bolts and nuts in two steps in numerical
order as shown in the figure.
5.
Connect injector harness connector.
6.
Install fuel pressure sensor, if removed.
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3
: O-ring (blue)
4
: Backup ring
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: Engine front
1st step
: 10.0 N·m (1.0 kg-m, 89 in-lb)
2nd step
: 20.5 N·m (2.1 kg-m, 15 ft-lb)
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EM-56
< REMOVAL AND INSTALLATION >
[MR16DDT ]
FUEL INJECTOR AND FUEL TUBE
7.
Install fuel rail insulator.
CAUTION:
• As covering part of fuel tube connector at the back end of common rail can easily move because
of its shape, do not remove it before installation.
• Install the insulator so that it is placed under lower side of intake manifold flange.
8.
Install in the reverse order of removal after this step.
Inspection
INFOID:0000000007577457
INSPECTION AFTER INSTALLATION
Check on Fuel Leakage
1.
Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there
are no fuel leakage at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.
2.
Start the engine. With engine speed increased, check again that there are no fuel leakage at connection
points.
CAUTION:
Never touch the engine immediately after stopped, as the engine becomes extremely hot.
Revision: 2011 October
2012 JUKE
IGNITION COIL, SPARK PLUG AND ROCKER COVER
EM-57
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IGNITION COIL, SPARK PLUG AND ROCKER COVER
Exploded View
INFOID:0000000007577458
Removal and Installation
INFOID:0000000007577459
REMOVAL
1.
Drain engine coolant. Refer to
2.
Remove engine cover. Refer to
.
3.
Remove air inlet tube assembly. Refer to
.
4.
Remove PCV hose.
5.
Remove rocker cover protector.
6.
Disconnect ignition coil harness connector, and them remove ignition coil.
CAUTION:
• Never drop or shock ignition coil.
1.
Rocker cover protector
2.
O-ring
3.
PCV control valve
4.
PCV hose
5.
Clamp
6.
Rocker cover gasket
7.
Rocker cover
8.
Clamp
9.
PCV hose
10. Oil filler cap
11. Spark plug
12. Ignition coil
A.
To intake manifold
B.
Comply with the assembly procedure
when tightning. Refer to
C.
To air duct
: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)
: Always replace after every disassembly.
JPBIA4303GB
Revision: 2011 October
2012 JUKE
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