Juke F15 (2012 year). Service Repair Manual

EM-12

< PREPARATION >

[MR16DDT ]

PREPARATION

(Kent-Moore No.)
Tool name

Description

(J-45488)
Quick connector release

Removing fuel tube quick connectors in en-
gine room

(

—

)

Spark plug wrench

Removing and installing spark plug
a: 14 mm (0.55 in)

(

—

)

Pulley holder

Crankshaft pulley removing and installing

(

—

)

Valve seat cutter set

Finishing valve seat dimensions

(

—

)

Piston ring expander

Removing and installing piston ring

(

—

)

Valve guide drift

Removing and installing valve guide

(

—

)

Valve guide reamer

1: Reaming valve guide inner hole
2: Reaming hole for oversize valve guide

PBIC0198E

JPBIA0399ZZ

ZZA1010D

S-NT048

S-NT030

PBIC4012E

PBIC4013E

PREPARATION

EM-13

< PREPARATION >

[MR16DDT ]

(J-43897-18)
(J-43897-12)
Oxygen sensor thread cleaner

Reconditioning the exhaust system threads
before installing a new air fuel ratio 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 oxygen sensor thread cleaning
tool when reconditioning exhaust system
threads

(

—

)

Manual lift table caddy

Removing and installing engine

(

—

)

Tube presser

Pressing the tube of liquid gasket

(Kent-Moore No.)
Tool name

Description

JPBIA0238ZZ

AEM489

ZZA1210D

S-NT052

EM-14

< BASIC INSPECTION >

[MR16DDT ]

CAMSHAFT VALVE CLEARANCE

BASIC INSPECTION

CAMSHAFT VALVE CLEARANCE

Inspection and Adjustment

INFOID:0000000006337234

INSPECTION

Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1.

Remove rocker cover. Refer to

EM-53, "Exploded View"

Measure the valve clearance with the following procedure:

Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) clockwise and align TDC mark (no

paint) (B) to timing indicator (A) on front cover.

• At the same time, check that both intake and exhaust cam

noses of No. 1 cylinder face inside (

) as shown in the figure.

• If they do not face inside, rotate crankshaft pulley once more

(360 degrees) and align as shown in the figure.

Use a feeler gauge, measure the clearance between valve lifter
and camshaft.

C : White paint mark (Not use for service)

PBIC3960E

: Camshaft (INT)

: Camshaft (EXH)

: Engine front

JPBIA4347ZZ

Valve clearance

: Refer to

EM-130, "Camshaft"

PBIC3192J

CAMSHAFT VALVE CLEARANCE

EM-15

< BASIC INSPECTION >

[MR16DDT ]

• By referring to the figure, measure the valve clearances at

locations marked “

” as shown in the table below [locations

indicated with black arrow (

) in the figure] with a feeler

gauge.

Set No. 4 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) one revolution (360 degrees) and

align TDC mark (no paint) (B) to timing indicator (A) on front
cover.

• By referring to the figure, measure the valve clearance at loca-

tions marked “

” as shown in the table below [locations indi-

cated with black arrow (

) in the figure] with a feeler gauge.

If out of standard, perform adjustment. Refer to “ADJUSTMENT”.

ADJUSTMENT

• Perform adjustment depending on selected head thickness of valve lifter.

Remove camshaft. Refer to

EM-78, "Exploded View"

Remove valve lifters at the locations that are out of the standard.

: Exhaust side

: No. 1 cylinder

: No. 2 cylinder

: No. 3 cylinder

: No. 4 cylinder

: Intake side

: Engine front

JPBIA4348ZZ

Measuring position

No. 1 CYL.

No. 2 CYL.

No. 3 CYL.

No. 4 CYL.

No. 1 cylinder at compression TDC

EXH

INT

C : White paint mark (Not use for service)

PBIC3960E

: Exhaust side

: No. 1 cylinder

: No. 2 cylinder

: No. 3 cylinder

: No. 4 cylinder

: Intake side

: Engine front

JPBIA4349ZZ

Measuring position

No. 1 CYL.

No. 2 CYL.

No. 3 CYL.

No. 4 CYL.

No. 4 cylinder at compression TDC

EXH

INT

EM-16

< BASIC INSPECTION >

[MR16DDT ]

CAMSHAFT VALVE CLEARANCE

Measure the center thickness of the removed valve lifters with a
micrometer (A).

Use the equation below to calculate valve lifter thickness for replacement.

• Thickness of new valve lifter (B) can be identified by stamp

mark (A) on the reverse side (inside the cylinder).

• Stamp mark “302” indicates 3.02 mm (0.1189 in) in thickness.

NOTE:
Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.1181 to 0.1378 in) in steps of 0.02
mm (0.0008 in) (when manufactured at factory). Refer to

EM-130, "Camshaft"

Install the selected valve lifter.

Install camshaft. Refer to

EM-78, "Exploded View"

Install timing chain and related parts. Refer to

EM-67, "Exploded View"

Manually rotate crankshaft pulley a few rotations.

Check that the valve clearances is within the standard. Refer to “INSPECTION”.

10. Install remaining parts in the reverse order of removal.

11. Warm up the engine, and check for unusual noise and vibration.

PBIC3195J

Valve lifter thickness calculation:

t = t

+ (C

– C

)

= Valve lifter thickness to be replaced

= Removed valve lifter thickness

= Measured valve clearance

= Standard valve clearance:

Intake

: 0.30 mm (0.012 in)

Exhaust

: 0.33 mm (0.013 in)

PBIC3196J

COMPRESSION PRESSURE

EM-17

< BASIC INSPECTION >

[MR16DDT ]

COMPRESSION PRESSURE

Inspection

INFOID:0000000006337235

Warm up engine thoroughly. Then, stop it.

Release fuel pressure. Refer to

EC-551, "Work Procedure"

Remove ignition coil and spark plug from each cylinder. Refer to

EM-53, "Exploded View"

Connect engine tachometer (not required in use of CONSULT-III).

Install compression gauge (B) with an adapter (A) (commercial
service tool) onto spark plug hole.

• Use the adapter whose picking up end inserted to spark plug

hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.

With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each
cylinder.

CAUTION:

Always use a fully charged battery to obtain the specified engine speed.
• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the

engine speed again with normal battery gravity.

• If compression pressure is below minimum value, check valve clearances, and parts associated with

combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, and cylinder
head gasket). After the checking, measure compression pressure again.

• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole

of the cylinder to recheck it for compression.

- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-

ton rings and replace if necessary.

- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-

functioning. Check valves for damage. Replace valve or valve seat accordingly.

• If two adjacent cylinders have respectively low compression pressure and their compression remains

low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.

After inspection is completed, install removed parts.

Start the engine, and check that the engine runs smoothly.

Perform trouble diagnosis. If DTC appears, erase it. Refer to

EC-147, "Description"

PBIC3541J

: 20 mm (0.79 in)

JPBIA0171ZZ

Compression pressure

: Refer to

EM-129, "General Specification"

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

EM-19

< SYMPTOM DIAGNOSIS >

[MR16DDT ]

Check specified noise source.

If necessary, repair or replace these parts.

A: Closely related

B: Related

C: Sometimes related

—: Not related

Location

of noise

Type of

noise

Operating condition of engine

Source of

noise

Check item

Refer-

ence page

Before

warm-

After

warm-

When

start-

ing

When

idling

When

racing

While

driving

Top of en-
gine
Rocker
cover
Cylinder
head

Ticking or
clicking

—

Tappet
noise

Valve clearance

EM-14

Rattle

—

Camshaft
bearing
noise

Camshaft journal oil
clearance
Camshaft runout

EM-130

Crank-
shaft pul-
ley
Cylinder
block
(Side of
engine)
Oil pan

Slap or
knock

—

Piston pin
noise

Piston to piston pin oil
clearance
Connecting rod bushing
oil clearance

EM-134

Slap or
rap

—

Piston
slap noise

Piston to cylinder bore
clearance
Piston ring side clear-
ance
Piston ring end gap
Connecting rod bend
and torsion

EM-134

Knock

Connect-
ing rod
bearing
noise

Connecting rod bushing
oil clearance
Connecting rod bearing
oil clearance

EM-134
EM-138

Knock

—

Main bear-
ing noise

Main bearing oil clear-
ance
Crankshaft runout

EM-138
EM-134

Front of
engine
Front cov-
er

Tapping or
ticking

—

Timing
chain and
chain ten-
sioner
noise

Timing chain cracks
and wear
Timing chain tensioner
operation

EM-76
EM-67

Front of
engine

Squeak-
ing or fizz-
ing

—

Drive belt
(Sticking
or slip-
ping)

Drive belt deflection

EM-20

Creaking

Drive belt
(Slipping)

Idler pulley bearing op-
eration

Squall
Creak

—

Water
pump
noise

Water pump operation

CO-22

EM-20

< PERIODIC MAINTENANCE >

[MR16DDT ]

DRIVE BELT

PERIODIC MAINTENANCE

DRIVE BELT

Exploded View

INFOID:0000000006337237

Checking

INFOID:0000000006337238

WARNING:

Perform this step when engine is stopped.
• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range

(A) in the figure.
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the fig-

ure.

• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.

Tension Adjustment

INFOID:0000000006337239

Removal and Installation

INFOID:0000000006337240

REMOVAL

Turn the steering wheel to the right.

Remove the front fender protector (RH) front side bolts and clips. And keep a service area. Refer to

EXT-

22, "Exploded View"

Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
a wrench securely. Then move the wrench handle in the direc-
tion of arrow (loosening direction of tensioner).

CAUTION:

Avoid placing hand in a location where pinching may occur
if the holding tool accidentally comes off.

Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole (B) of the retaining boss to
fix drive belt auto-tensioner.
• Keep drive belt auto-tensioner pulley arm locked after drive

belt is removed.

Remove drive belt.

Alternator

Drive belt auto-tensioner

Crankshaft pulley

A/C compressor

Water pump

Drive belt

Possible use range

Range when new drive belt is in-
stalled

Indicator

JPBIA4302ZZ

Refer to

EM-129, "Drive Belt"

JPBIA4351ZZ

DRIVE BELT

EM-21

< PERIODIC MAINTENANCE >

[MR16DDT ]

INSTALLATION

Install drive belt.

CAUTION:

• Confirm drive belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each

pulley groove.

Release drive belt auto-tensioner, and apply tension to drive belt.

Turn crankshaft pulley clockwise several times to equalize tension between each pulley.

Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to

EM-20, "Exploded View"

SPARK PLUG

EM-23

< PERIODIC MAINTENANCE >

[MR16DDT ]

SPARK PLUG

Exploded View

INFOID:0000000006430455

Removal and Installation

INFOID:0000000006337243

REMOVAL

Remove engine cover. Refer to

EM-25, "Exploded View"

Remove air inlet tube assembly. Refer to

EM-31, "Exploded View"

Remove ignition coil.

Rocker cover protector

O-ring

PCV valve

PCV hose

Clamp

Rocker cover gasket

Rocker cover

Clamp

PCV hose

10. Oil filler cap

11. Spark plug

12. Ignition coil

To air duct assembly

Tightening must be done following
the installation procedure.
Refer to

EM-53

To intake manifold

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA4303GB

EM-24

< PERIODIC MAINTENANCE >

[MR16DDT ]

SPARK PLUG

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:0000000006337244

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.

• Spark plug gap adjustment is not required between replace-

ment intervals.

• Measure spark plug gap. when it exceeds the limit, replace

spark plug even if it is with in the specified replacement mile-
age. Refer to

EM-129, "Spark Plug"

: 14 mm (0.55 in)

JPBIA0030ZZ

Spark plug (Standard type)

: Refer to

EM-129, "Spark Plug"

Cleaner air pressure

: Less than 588 kPa (6 kg/cm

85 psi)

Cleaning time

: Less than 20 seconds

SMA773C

JPBIA0031ZZ

ENGINE COVER

EM-25

< REMOVAL AND INSTALLATION >

[MR16DDT ]

REMOVAL AND INSTALLATION

ENGINE COVER

Exploded View

INFOID:0000000006337245

Removal and Installation

INFOID:0000000006337246

REMOVAL

Remove engine cover.

CAUTION:

Never damage or scratch engine cover when installing or removing.

INSTALLATION

Install in the reverse order of removal.

Engine cover

Mounting rubber

JPBIA4311ZZ

EM-26

< REMOVAL AND INSTALLATION >

[MR16DDT ]

AIR CLEANER AND AIR DUCT

AIR CLEANER AND AIR DUCT

Exploded View

INFOID:0000000006337249

Removal and Installation

INFOID:0000000006337250

REMOVAL

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

Remove air duct (duct side).

Remove engine cover. Refer to

EM-25, "Exploded View"

Remove the air cleaner filter from the air cleaner case.

Disconnect mass air flow sensor harness connector, and remove harness clamp from air cleaner body.

Remove air cleaner body assembly.

Remove the air duct (between air cleaner case assembly and turbocharger air duct).
• Add matching marks if necessary for easier installation.

Mass air flow sensor

Gasket

Clamp

Air duct (suction side)

Clamp

Air cleaner cover assembly

Mounting rubber

Air cleaner filter

Air cleaner body assembly

10. Air duct with resonator

11.

Grommet

12. Air duct (duct side)

13. Grommet

14. Bracket

15. Mounting rubber

To turbocharger

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA4305GB

AIR CLEANER AND AIR DUCT

EM-27

< REMOVAL AND INSTALLATION >

[MR16DDT ]

Remove air cleaner cover assembly.

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.

Remove air duct with resonator with the following procedure.

Remove fender protector (LH). Refer to

EXT-22, "Exploded View"

Remove air duct with resonator.

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:0000000006337251

INSPECTION AFTER REMOVAL

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

Juke F15 (2012 year). Service Repair Manual - part 179