Juke F15 (2012 year). Service Repair Manual - part 181

EM-44

< REMOVAL AND INSTALLATION >

[MR16DDT ]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

Disconnect harness connector (A) with the following procedure.

Disconnect fuel feed hose (1) from clamp (2).

Disengage (A) and pull up (B) the pawl of the fuel feed hose
conector retainer (C) to disconnect the fuel feed tube from high
pressure fuel pump.
NOTE:
If the fuel feed hose is stuck, hold the fuel pipe by hand and dis-
connect it by pusing 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).
• Do not remove the retainer.
• Prepare container and colth beforehand as fuel will leak

out.

• Never pull with lateral force applied. O-ring inside quick

connector may be damaged.

• To keep clean the connecting portion and to avoid dam-

age and foreign materials, cover them completely with
plastic bags (A), etc. or a similar item.

Remove intake manifold. Refer to

EM-29, "Removal and Installation"

Remove fuel feed tube.

Remove high pressure fuel pump and lifter.

INSTALLATION

Install high pressure pump with the following procedure.

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Retainer color

: Red

JPBIA4377ZZ

JPBIA4378ZZ

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

EM-45

< REMOVAL AND INSTALLATION >

[MR16DDT ]

Check the orientation of oil pump cam from the mounting area
(view arrow) of high pressure fuel pump.

Aim oil pump cam at the BTC area (arrow position).

NOTE:
For BTC area, anywhere whithin the area indicated by arrow can
be accepted.

Install O-ring to high pressure fuel pump. When handing new O-ring, paying attention to the following cau-
tion items:

CAUTION:

• 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.

Install valve lifter.

Apply oil to the fitting area of high pressure O-ring and cam shaft bracket side to install high pressure
pump.

Connect fuel feed hose with the following procedure, and them install the fuel feed hose.

Check no foreign substances are deposited in and around matching pipe and quick connector.

Quick connector shall be inserted gradually, aligning with the axis of the matching pipe.

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.

After attaching the quick connector and fix the hose to the clamp.

Install in the reverse order of removal after this step.

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: Camshaft (EXH)

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: Lock position

: Unlock position

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EM-46

< REMOVAL AND INSTALLATION >

[MR16DDT ]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

Inspection

INFOID:0000000006337268

INSPECTION AFTER INSTALLATION

Check for Fuel Leakage

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.

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.

FUEL INJECTOR AND FUEL TUBE

EM-47

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL INJECTOR AND FUEL TUBE

Exploded View

INFOID:0000000006337269

CAUTION:

Never remove or disassemble parts unless instructed as shown in the figure.

Removal and Installation

INFOID:0000000006337270

WARNING:

• Be sure to read

EM-7, "Precaution for Handling High Pressure Fuel System"

when working on the

high pressure fuel system.

• Put a “CAUTION: FLAMMABLE” sign in the workshop.

Holder

Seal ring (white)

Backup ring

O-ring (blue)

Fuel injector

Stud bolt

Fuel tube assembly

Fuel tube insulator

Fuel tube protector

10. Fuel pressure sensor

11. O-ring

12. Fuel tube adaptor

13. Backup ring (white)

14. Backup ring (brown)

15. O-ring (black)

To fuel tube

Tighting must be done following the in-
stallation procedure. Refer to

EM-47

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

: Should be lubricated with oil.

JPBIA4314GB

EM-48

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL INJECTOR AND FUEL TUBE

• Be sure to work in a well ventilated area and furnish workshop with a CO

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

Release the fuel pressure. Refer to

EC-140, "Work Procedure"

Remove front bumper. Refer to

EXT-12, "Exploded View"

Remove charge are cooler. Refer to

EM-31, "Exploded View"

Remove oil level gauge. Refer to

EM-40, "Exploded View"

Remove intake manifold. Refer to

EM-28, "Exploded View"

Remove alternator. Refer to

CHG-30, "MR16DDT : Exploded View"

Remove oil level gauge guide. Refer to

EM-40, "Exploded View"

Remove fuel tube protector, and them remove fuel tube insulator.

Remove high pressure pump insulator. Refer to

EM-43, "Exploded View"

10. Remove fuel tube. Refer to

EM-43, "Exploded View"

11. Disconnect fuel pressure sensor harness connector.
12. Disconnect fuel injector harness connector.

13. Remove fuel tube.

• 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 tube.

14. Remove fuel pressure sensor and fuel tube adaptor, if necessary.
15. Remove fuel injector from cylinder head as per the following.

CAUTION:

• Be careful with remaining fuel that may go out from fuel tube.
• Be careful no to damage injector nozzles during removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector.

Remove injector holder.

Install an remover [SST: KV10119600] (A) to the injector con-
nector side so that cutout (B) of injector remover faces the injec-
tor connector side.

: Engine front

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JPBIA4382ZZ

FUEL INJECTOR AND FUEL TUBE

EM-49

< REMOVAL AND INSTALLATION >

[MR16DDT ]

• Hook pawl portion (B) of injector remover [SST: KV10119600]

(A) to groove portion (C) of injector

Press down body portion (A) of injector remover [SST:
KV10119600] until it contacts cylinder head.

Tighten injector remover [SST: KV10119600] clockwise and
remove injector from cylinder head.

Cut teflon seal (1) while pinching it. Be careful not to damage
injector.

Remove insulator from mounting hole of fuel injector of cylinder
head.

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JPBIA4383ZZ

JPBIA4384ZZ

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EM-50

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL INJECTOR AND FUEL TUBE

INSTALLATION

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.

Install an injector seal drift set [SST: KV101197S0 (—)] (A) to
fuel injector (1).

Set seal ring (1) to injector seal drift set [SST: KV101197S0 (—)]
(A).

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.

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.

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:

• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.

JPBIA4386ZZ

JSBIA0348ZZ

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FUEL INJECTOR AND FUEL TUBE

EM-51

< REMOVAL AND INSTALLATION >

[MR16DDT ]

• 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.

Install fuel injector (1) to fuel rail (2) as per the following:

Install fuel injector holder (5) to fuel injector.

CAUTION:

• Never reuse 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.

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).

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.

Insert insulator into mounting hole of fuel injector of cylinder head.

Install fuel pressure sensor, if removed.

Install fuel tube adaptor, if removed.
• Install O-ring and backup ring to fuel tube adaptor. When handing new O-ring and backup ring, paying

attention to the following caution items:

CAUTION:

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 in the right direction as instructed.

JPBIA3864ZZ

: O-ring (blue)

: Backup ring

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EM-52

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL INJECTOR AND FUEL TUBE

- Since the cross sections of fuel tube adapter and back up ring are tapered, be careful with the

mounting direction.

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.

Connect injector harness connector.

Install in the reverse order of removal after this step.

Inspection

INFOID:0000000006337271

INSPECTION AFTER INSTALLATION

Check on Fuel Leakage

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.

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.

: 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)

JPBIA4388ZZ

IGNITION COIL, SPARK PLUG AND ROCKER COVER

EM-53

< REMOVAL AND INSTALLATION >

[MR16DDT ]

IGNITION COIL, SPARK PLUG AND ROCKER COVER

Exploded View

INFOID:0000000006337242

Removal and Installation

INFOID:0000000006337273

REMOVAL

Drain engine coolant. Refer to

CO-11, "Draining"

Remove engine cover. Refer to

EM-25, "Exploded View"

Remove intake manifold. Refer to

EM-28, "Exploded View"

Remove air inlet tube assembly. Refer to

EM-31, "Exploded View"

Remove PCV hose.

Remove rocker cover protector.

Disconnect ignition coil harness connector, and them remove ignition coil.

Rocker cover protector

O-ring

PCV control 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 turbocharger inlet tube

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JPBIA4303GB

EM-54

< REMOVAL AND INSTALLATION >

[MR16DDT ]

IGNITION COIL, SPARK PLUG AND ROCKER COVER

CAUTION:

• Never drop or shock ignition coil.
• Never disassemble ignition coil.

Move ignition harness.

Remove rocker cover.
• Loosen bolts in reverse order shown in the figure.

10. Remove PCV valve and PCV hose, if necessary.
11. Remove rocker cover gasket from rocker cover.

INSTALLATION

Install the rocker cover gasket to rocker cover.

CAUTION:

Check the gasket is not dropped.

Install rocker cover.
• Tighten bolts in two steps separately in numerical order as

shown in the figure.

Install in the reverse order of removal, for the rest of parts.

: Engine front

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: Engine front

1st step

: 1.96 N·m (0.20 kg-m, 17 in-lb)

2nd step

: 8.33 N·m (0.85 kg-m, 74 in-lb)

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ENGINE ASSEMBLY

EM-55

< UNIT REMOVAL AND INSTALLATION >

[MR16DDT ]

UNIT REMOVAL AND INSTALLATION

ENGINE ASSEMBLY

2WD

2WD : Exploded View

INFOID:0000000006337287

CAUTION:

Check that the stud bolt (*2) is tight at the specified torque before tightening the mounting nut (*1)
shown in the figure. [Stud bolt (*2) may be loosened after loosening the mounting nut (*1)]

2WD : Removal and Installation

INFOID:0000000006337288

WARNING:

• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.

Washer

Upper torque rod (RH)

Engine mounting insulator (RH)

Rear torque rod bracket

Rear torque rod

Engine mounting insulator (LH)

Engine mounting frame support (LH) 8.

Engine mounting bracket (LH)

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

JPBIA4346GB

EM-56

< UNIT REMOVAL AND INSTALLATION >

[MR16DDT ]

ENGINE ASSEMBLY

• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.

CAUTION:

• Always be careful to work safely, avoid forceful or uninstructed operations.
• Never start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-

able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.

• For supporting points for lifting and jacking point at rear axle, refer to

GI-36, "Garage Jack and

Safety Stand and 2-Pole Lift"

REMOVAL

Outline

Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.

Preparation

Release fuel pressure. Refer to

EC-140, "Work Procedure"

Drain engine coolant from radiator. Refer to

CO-11, "Draining"

CAUTION:

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

Remove the following parts.
• Engine undercover
• Front road wheels and tires
• Front fender protector (RH and LH): Refer to

EXT-22, "Exploded View"

• Drive belt: Refer to

EM-20, "Removal and Installation"

• Engine cover: Refer to

EM-25, "Exploded View"

• Battery and battery tray: Refer to

PG-124, "Exploded View"

• Air duct, and air cleaner case assembly and air cleaner body assembly: Refer to

EM-26, "Exploded

View"

• Radiator hose (upper and lower): Refer to

CO-17, "Exploded View"

• Exhaust front tube: Refer to

EX-5, "Exploded View"

• Radiator cooling fan assembly: Refer to

CO-20, "Exploded View"

• Charger air cooler: Refer to

EM-31, "Exploded View"

• Alternator: Refer to

CHG-30, "MR16DDT : Exploded View"

Engine Room LH

Disconnect all connections of engine harness around the battery, and then temporarily secure the engine
harness into the engine side.

CAUTION:

Protect connectors using a resin bag against foreign materials during the operation.

Disconnect fuel feed hose quick connector. Refer to

EM-43, "Exploded View"

Disconnect heater hoses. Refer to

CO-26, "Exploded View"

Disconnect control linkage from transaxle. Refer to

TM-78, "Exploded View"

Remove EVAP hoses. Refer to

EM-28, "Exploded View"

Disconnect clutch tube on transaxle side from clutch damper. Refer to

CL-24, "Exploded View"

Engine Room RH

Disconnect vacuum hose from intake manifold. Refer to

EM-28, "Exploded View"

Remove A/C compressor. Refer to

HA-86, "Exploded View"

Remove ground cable at engine side.

Vehicle Underbody

Remove ground cable at transaxle side.

Remove drive shafts (RH and LH). Refer to

FAX-21, "Exploded View"

Remove rear torque rod.

Remove stabilizer connecting rod. Refer to

FSU-16, "Exploded View"

ENGINE ASSEMBLY

EM-57

< UNIT REMOVAL AND INSTALLATION >

[MR16DDT ]

Remove front suspension member. Refer to

FSU-18, "Exploded View"

Preparation for the separation work of transaxle is as follows:
• Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to

EM-99, "Exploded

View"

Removal

Use a manual lift table caddy (commercial service tool) (A) or
equivalently rigid tool such as a transmission jack. Securely sup-
port bottom of the engine and the transaxle assembly.

CAUTION:

Put a piece of wood or an equivalent as the supporting sur-
face, secure a completely stable condition.

Remove upper torque rod (1), and engine mounting insulator
(RH) (2).

Remove engine mounting bracket (LH) through bolt-securing
nut (B).

Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work,
observe the following caution.

CAUTION:

• Check that no part interferes with the vehicle side.
• Before and during this lifting, always check if any harnesses are left connected.
• During the removal, always be careful to prevent the vehicle from falling off the lift due to

changes in the center of gravity.

• If necessary, support the vehicle by setting jack or suitable tool at the rear.

Separation

PBIC3223J

: Vehicle front

JPBIA4419ZZ

: Engine mounting insulator (LH)

: Engine mounting bracket support (LH)

: Through not

: Vehicle front

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EM-58

< UNIT REMOVAL AND INSTALLATION >

[MR16DDT ]

ENGINE ASSEMBLY

Install engine slinger to front cover front left side (A) and cylinder
head rear right side (B).

Remove starter motor. Refer to

STR-27, "MR16DDT : Exploded View"

Lift with a hoist and separate the engine from the transaxle assembly. Refer to

TM-84, "MR16DDT :

Exploded View"

INSTALLATION

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

CAUTION:

• Never allow engine oil to get on engine mounting insulator. Be careful not to damage engine mount-

ing insulator.

• Check that each mounting insulator is seated properly, and tighten mounting nuts and bolts.
• When installation directions are specified, install parts according to the direction marks on them

referring to the figure of components. Refer to

EM-55, "2WD : Exploded View"

Rear torque rod bracket

Temporarily tighten mounting bolts in the numerical order as
shown in the figure.

Tighten mounting bolts to the specified torque in the numerical
order as shown in the figure.

2WD : Inspection

INFOID:0000000006709022

INSPECTION AFTER INSTALLATION

Inspection for Leakage

The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required

quantity, fill to the specified level. Refer to

MA-13, "Fluids and Lubricants"

• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-

age at connection points.

- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including

engine oil and engine coolant.

• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the

specified level, if necessary.

Summary of the inspection items:

: Engine front

Slinger bolts

Front cover front left
side:

: 32.9 N·m (3.4 kg-m, 24 ft-lb)

Cylinder head rear
right side:

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

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: Vehicle front

JPBIA4416ZZ

Items

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

ENGINE ASSEMBLY

EM-59

< UNIT REMOVAL AND INSTALLATION >

[MR16DDT ]

*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

4WD

4WD : Exploded View

INFOID:0000000006430457

4WD : Removal and Installation

INFOID:0000000006430458

WARNING:

• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Fuel

Leakage

Exhaust gases

—

Leakage

—

Washer

Upper torque rod (RH)

Engine mounting insulator (RH)

Rear engine mounting bracket

Rear torque rod

Engine mounting insulator (LH)

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

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