Content .. 187 188 189 190 ..

Juke F15 (2012 year). Service Repair Manual - part 189

EM-172

< REMOVAL AND INSTALLATION >

[HR16DE]

OIL PAN (LOWER)

Apply a continuous bead of liquid gasket (B) with a tube presser
(commercial service tool) as shown in the figure.

Use Genuine Liquid Gasket or equivalent.

CAUTION:

Attaching should be done within 5 minutes after liquid gas-
ket application.

Tighten bolts in numerical order as shown in the figure.

Install oil pan drain plug.
• Refer to the figure of components of former page for installation direction of drain plug washer. Refer to

EM-169, "Exploded View"

Install in the reverse order of removal after this step.
NOTE:
Wait at last 30 minutes after oil pan (lower) is installed before pouring engine oil.

Inspection

INFOID:0000000006449907

INSPECTION AFTER REMOVAL

Clean oil strainer if any object attached.

INSPECTION AFTER INSTALLATION

Check the engine oil level and adjust engine oil. Refer to

LU-25, "Inspection"

Start engine, and check there is no leakage of engine oil.

Stop engine and wait for 10 minutes.

Check the engine oil level again. Refer to

LU-25, "Inspection"

: 7.5 - 9.5 mm (0.295 - 0.374 in)

4.0 - 5.0 mm (0.157 - 0.197 in)

: Oil pan (lower)

: Engine outside

JPBIA4746ZZ

: Engine front

JPBIA4744ZZ

FUEL INJECTOR AND FUEL TUBE

EM-173

< REMOVAL AND INSTALLATION >

[HR16DE]

FUEL INJECTOR AND FUEL TUBE

Exploded View

INFOID:0000000006449908

CAUTION:

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

Removal and Installation

INFOID:0000000006449909

WARNING:

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

REMOVAL

Release the fuel pressure. Refer to

EC-551, "Work Procedure"

Remove intake manifold. Refer to

EM-163, "Exploded View"

Stud bolt

O-ring (green)

Fuel injector (front)

Clip

Fuel injector (rear)

O-ring (black)

Fuel tube protector

Fuel tube

Fuel feed hose

10. Quick connector cap

To centralized under-floor piping

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Should be lubricated with oil.

JPBIA4093GB

EM-174

< REMOVAL AND INSTALLATION >

[HR16DE]

FUEL INJECTOR AND FUEL TUBE

Disconnect quick connector with the following procedure. Dis-
connect fuel feed hose from fuel tube.

NOTE:
There is no fuel return path.

Remove quick connector cap (engine side) (1) from quick con-
nector connection.

Disconnect fuel feed hose from hose clamp.

With the sleeve side of quick connector release facing quick connector, install quick connector release
(commercial service tool) onto fuel tube.

Insert quick connector release (A) into quick connector (2) until
sleeve (B) contacts and goes no further. Hold quick connector
release on that position.

CAUTION:

Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.

Draw and pull out quick connector straight from fuel tube (1).

CAUTION:

• Pull quick connector (E) holding position (C) in the figure.
• Never pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will leakage out.
• Avoid fire and sparks.
• 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 bend or twist connection between quick connector and fuel feed tube during installation/

removal.

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

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

Disconnect harness connector from fuel injector.

: Quick connector cap

JPBIA4130ZZ

JPBIA4131ZZ

D : Insert and retain

JPBIA2255ZZ

JPBIA2888ZZ

FUEL INJECTOR AND FUEL TUBE

EM-175

< REMOVAL AND INSTALLATION >

[HR16DE]

Remove fuel tube protector.
• Loosen mounting bolts in reverse order as shown in the figure.

Remove fuel tube and fuel injector assembly.
• 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.

Remove fuel injector from fuel tube with the following procedure:

Open and remove clip (1).

Remove fuel injector (3) and (4) from fuel tube (2) by pulling
straight.

CAUTION:

• Be careful with remaining fuel that may go out from fuel

tube.

• Be careful not to damage fuel injector nozzle during

removal.

• Never bump or drop fuel injector.
• Never disassemble fuel injector.

INSTALLATION

Note the following, and install O-rings to fuel injector.

CAUTION:

• Upper and lower O-rings are different. Be careful not to confuse them.

• 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 is stretched while installing, never insert it quickly into fuel tube.

• Insert O-ring straight into fuel tube. Never decenter or twist it.

Install fuel injector to fuel tube with the following procedure:

: Engine front

JPBIA4132ZZ

: Engine front

JPBIA4133ZZ

JPBIA4134ZZ

Fuel tube side

: Black

Nozzle side

: Green

EM-176

< REMOVAL AND INSTALLATION >

[HR16DE]

FUEL INJECTOR AND FUEL TUBE

Insert clip (2) into clip mounting groove on fuel injector (4).

• Insert clip so that protrusion (F) of fuel injector matches cut-out

(D) of clip.

CAUTION:

• Never reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If

interference occurs, replace O-ring.

Insert fuel injector into fuel tube (1) with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (B) of fuel tube matches

cut-out (C) of clip.

• Check that fuel tube flange (A) is securely fixed in flange fixing

groove (E) on clip.

Check that installation is complete by checking that fuel injector
does not rotate or come off.

Set fuel tube and fuel injector assembly at its position for installation on cylinder head.

CAUTION:

For installation, be careful not to interfere with fuel injector nozzle.

Install fuel tube and injector assembly onto cylinder.
• Tighten mounting bolts in numerical order as shown in the fig-

ure.

Install fuel tube protector.
• Tighten mounting bolts in numerical order as shown in the fig-

ure.

Connect harness connector to fuel injector.

Connect fuel feed tube with the following procedure.

Check for damage or foreign material on the fuel tube and quick connector.

Apply new engine oil lightly to area around the top of fuel tube.

Align center to insert quick connector straightly into fuel tube.

: O-ring (black)

: O-ring (green)

JPBIA4530ZZ

: Engine front

JPBIA4133ZZ

: Engine front

JPBIA4133ZZ

FUEL INJECTOR AND FUEL TUBE

EM-177

< REMOVAL AND INSTALLATION >

[HR16DE]

• Insert quick connector (1) to fuel tube until the top spool (C) on

fuel tube is inserted completely and the 2nd level spool (D) is
positioned slightly below quick connector bottom end.

CAUTION:

• Hold (A) position in the figure when inserting fuel tube

into quick connector.

• Carefully align center to avoid inclined insertion to pre-

vent damage to O-ring inside quick connector.

• Insert until you hear a “click” sound and actually feel

the engagement.

• To avoid misidentification of engagement with a similar sound, be sure to perform the next

step.

Pull quick connector hard by hand holding position. Check it is completely engaged (connected) so that it
does not come out from fuel tube.

Install quick connector cap (engine side) (1) to quick connector
connection.
• Install quick connector cap (engine side) with the side arrow

facing quick connector side (fuel feed tube side).

CAUTION:

• Check that the quick connector and fuel tube are

securely engaged with the quick connector cap (engine
side) mounting groove.

• Quick connector may not be connected correctly if

quick connector cap (engine side) cannot be installed
easily. Remove the quick connector cap (engine side),
and then check the connection of quick connector
again.

Install fuel feed hose to hose clamp.

Install remaining parts in the reverse order of removal.

Inspection

INFOID:0000000006449910

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.

: Upright insertion

: Fitted condition

JPBIA2256ZZ

JPBIA4131ZZ

EM-178

< REMOVAL AND INSTALLATION >

[HR16DE]

IGNITION COIL, SPARK PLUG AND ROCKER COVER

IGNITION COIL, SPARK PLUG AND ROCKER COVER

Exploded View

INFOID:0000000006449911

Removal and Installation

INFOID:0000000006449912

REMOVAL

Ignition coil

Spark plug

Rocker cover

Hose cramp

PCV hose

PCV valve

O-ring

Gasket

Oil filler cap

10.

O-ring

11.

Camshaft position sensor (INT)

12.

Camshaft position sensor (EXH)

13.

Cramp

To intake manifold

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Sealing point

: Should be lubricated with oil.

JPBIA4094GB

IGNITION COIL, SPARK PLUG AND ROCKER COVER

EM-179

< REMOVAL AND INSTALLATION >

[HR16DE]

Remove intake manifold. Refer to

EM-163, "Exploded View"

Remove ignition coil.

CAUTION:

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

Remove fuel tube protector. Refer to

EM-173, "Exploded View"

Remove PCV hose from rocker cover.

Remove PCV valve, if necessary.

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

Remove rocker cover gasket from rocker cover.

Use scraper to remove all traces of liquid gasket from cylinder head and front cover.

CAUTION:

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

INSTALLATION

Rocker cover with the following procedure:

Press gasket onto the bosses for the rocker cover bolt holes as
shown in the figure to prevent the rocker cover from dropping
off.

Apply liquid gasket to the position as shown in the figure.

Use Genuine Liquid Gasket or equivalent.

Install rocker cover to cylinder head.

CAUTION:

Check the gasket is not dropped.

: Engine front

JPBIA4135ZZ

JPBIA4136ZZ

: Cylinder head

: Front cover

2.5 - 3.5 mm

JPBIA4137ZZ

EM-180

< REMOVAL AND INSTALLATION >

[HR16DE]

IGNITION COIL, SPARK PLUG AND ROCKER COVER

• Tighten bolts in two steps separately in numerical order as

shown in the figure.

Install PCV valve.
• Insert PCV valve until the flange of PCV valve contact the grommet absolutely.

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

: Engine front

JPBIA4135ZZ

TIMING CHAIN

EM-181

< REMOVAL AND INSTALLATION >

[HR16DE]

TIMING CHAIN

Exploded View

INFOID:0000000006449913

Timing chain slack guide

Timing chain tensioner

Camshaft sprocket (EXH)

Camshaft sprocket (INT)

Plug

Front oil seal

Crankshaft pulley

Crankshaft pulley bolt

Front cover

10. Crankshaft sprocket

11. Crankshaft sprocket key

12. Oil pump sprocket

13. Oil pump drive chain

14. Oil pump drive chain tensioner

15. Timing chain

16. Timing chain tension guide

Tightening must be done following the installation procedure.
Refer to

EM-182

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Sealing point

: Should be lubricated with oil.

JPBIA4095GB

EM-182

< REMOVAL AND INSTALLATION >

[HR16DE]

TIMING CHAIN

Removal and Installation

INFOID:0000000006449914

CAUTION:

The rotation direction indicated in the text indicates all directions seen from the engine front direction.

REMOVAL

Remove front road wheel (RH).

Remove front fender protector (RH). Refer to

EXT-22, "Exploded View"

Drain engine oil. Refer to

LU-26, "Draining"

NOTE:
Perform this step when engine is cold.

Remove the following parts.
• Rocker cover: Refer to

EM-178, "Exploded View"

• Drive belt: Refer to

EM-155, "Removal and Installation"

• Water pump pulley: Refer to

CO-22, "Exploded View"

Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket and insulator (RH). Refer to

EM-215, "Exploded View"

Set No. 1 cylinder at TDC of its compression stroke with the following procedure:

Rotate crankshaft pulley (2) clockwise and align TDC mark
(without paint mark) (A) to timing indicator (1) on front cover.

Check the matching marks on each camshaft sprocket are posi-
tioned as shown in the figure.

• If not, rotate crankshaft pulley one more turn to align matching

marks to the positions in the figure.

Remove crankshaft pulley with the following procedure:

Secure crankshaft pulley (1) using a pulley holder (commercial
service tool) (A).

Loosen and pull out crankshaft pulley bolts.

CAUTION:

Never remove the mounting bolts as they will be used as a
supporting point for the pulley puller [SST: KV11103000].

: White paint mark (Not use for service)

PBIC3673E

: Timing chain

: Camshaft sprocket (EXH)

: Camshaft sprocket (INT)

: Matching mark (Peripheral knurls)

: Matching mark (stamp)

: Matching mark (Peripheral groove)

JPBIA4138ZZ

PBIC3710E

TIMING CHAIN

EM-183

< REMOVAL AND INSTALLATION >

[HR16DE]

Attach a pulley puller [SST: KV11103000] (A) in the M 6 thread
hole on crankshaft pulley, and remove crankshaft pulley.

Remove front cover with the following procedure:

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

Cut liquid gasket by prying the position (

) as shown in the fig-

ure, and then remove the front cover.

Remove front oil seal from front cover.
• Remove by lifting it up using a suitable tool.

CAUTION:

Be careful not to damage the front cover.

: M6 bolt

PBIC3711E

JPBIA4139ZZ

JPBIA4140ZZ

EM-184

< REMOVAL AND INSTALLATION >

[HR16DE]

TIMING CHAIN

10. Remove chain tensioner (1) with the following procedure.

Fully push down the chain tensioner lever (A), and then push the
plunger (C) into the inside of tensioner.
• The tab (B) is released by fully pushing the lever down. As a

result, the plunger can be moved.

Pull up the lever to align its hole position with the body hole posi-
tion.
• When the lever hole is aligned with the body hole position, the

plunger is fixed.

• When the protrusion parts of the plunger ratchet and the tab

face each other, both hole positions are not aligned. At that
time, correctly engage them and align these hole positions by
slightly moving the plunger.

Insert the stopper pin (D) into the body hole through the lever hole, and then fix the lever at the upper
position.
• Figure shows the example that a hexagonal wrench for 2.5 mm (0.098 in) is used.

Remove chain tensioner.

11. Remove the timing chain tension guide (2) and the timing chain

slack guide (1).

12. Remove the timing chain (2).

• Pull the looseness of timing chain toward the camshaft

sprocket (EXH) (1), and then remove the timing chain and
start the removal from camshaft sprocket (EXH) side.

CAUTION:

Never rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.

13. Remove the crankshaft sprocket and the oil pump drive related parts with the following procedure.
a.

Remove chain tensioner (1).
• Pull out from the shaft (B) and spring fixing holes (A).

PBIC3713E

JPBIA4141ZZ

JPBIA4142ZZ

JPBIA4143ZZ

TIMING CHAIN

EM-185

< REMOVAL AND INSTALLATION >

[HR16DE]

Hold the top of the oil pump shaft using the TORX socket (size:
E8), and then loosen the oil pump sprocket nuts and remove
them.

Remove the crankshaft sprocket (1), the oil pump drive chain
(2), and the oil pump sprocket (3) at the same time.

INSTALLATION

NOTE:
The figure shows the relationship between the matching mark on
each timing chain and that on the corresponding sprocket, with the
components installed.

Install the crankshaft sprocket and the oil pump drive related parts with the following procedure:

Install the crankshaft sprocket (1), the oil pump drive chain (2),
and the oil pump sprocket (3) at the same time.

• Install the crankshaft sprocket so that its invalid gear area (A)

is towards the back of the engine.

• Install the oil pump sprocket so that its hexagonal surface

faces (B) the front of engine.

NOTE:
There is no matching mark in the oil pump drive related parts.

JPBIA4230ZZ

: Camshaft sprocket (EXH)

: Timing chain

: Timing chain slack guide

: Chain tensioner

: Crankshaft sprocket

: Oil pump drive chain

: Oil pump sprocket

: Timing chain tension guide

: Camshaft sprocket (INT)

: Matching mark (Peripheral groove)

: Pink link

: Matching mark (Peripheral knurls)

: Orange link

: Matching mark (stamp)

: Crankshaft key (point straight up)

JPBIA4223ZZ

: Engine front

PBIC3719E

EM-186

< REMOVAL AND INSTALLATION >

[HR16DE]

TIMING CHAIN

Hold the top of the oil pump shaft using the TORX socket (size:
E8), and then tighten the oil pump sprocket nuts.

Install chain tensioner (1).
• Insert the body into the shaft (B) while inserting the spring into

the fixing hole (A) of cylinder block front surface.

• Check that the tension is applied to the oil pump drive chain

after installing.

Install timing chain with the following procedure.

• Install by aligning matching marks on each sprocket and tim-

ing chain.

• If these matching marks are not aligned, rotate the camshaft

slightly to correct the position.

CAUTION:

• For the following note, after the matching marks are

aligned, keep them aligned by holding them with a hand.

• To avoid skipped teeth, never rotate crankshaft and cam-

shaft until front cover is installed.

Install timing chain tension guide (2) and timing chain slack
guide (1).

: Crankshaft sprocket

: Oil pump drive chain

: Oil pump sprocket

JPBIA4230ZZ

JPBIA4143ZZ

: Matching mark (Peripheral groove)

: Pink link

: Matching mark (Peripheral knurls)

: Orange link

: Matching mark (stamp)

: Crankshaft key (point straight up)

JPBIA4144ZZ

JPBIA4141ZZ

TIMING CHAIN

EM-187

< REMOVAL AND INSTALLATION >

[HR16DE]

Install chain tensioner (1).
• Fix the plunger at the most compressed position using a stop-

per pin (A), and then install it.

• Securely pull out the stopper pin after installing the chain ten-

sioner.

Check matching mark position of timing chain and each sprocket again.

Install the front oil seal to the front cover. Refer to

EM-206, "FRONT OIL SEAL : Removal and Installation"

Install front cover with the following procedure:

Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to front cover as shown in the figure.
Use Genuine Liquid Gasket or equivalent.

PBIC3722E

: Cylinder head

: Cylinder block

: Oil pan (upper)

: Liquid gasket application area [

3.0 - 4.0 mm (0.12 - 0.16 in)]

JPBIA4145ZZ

Content .. 187 188 189 190 ..