Juke F15 (2012 year). Service Repair Manual - part 198

EM-316

< REMOVAL AND INSTALLATION >

[K9K]

CYLINDER HEAD

Push the valve stem seal past the tool barrel, then withdraw the
barrel.

Place the guide tube plus push rod assembly on the valve stem
seal.

Push the valve stem seal down by tapping the top of the sleeve
with the palm of your hand until the guide tube reaches the cylin-
der head.

Repeat these operations for all the valves.

Install the valve springs and upper cups using valve spring com-
pressor.

10. Install the keys using tweezers.

MBIB0424E

MBIB0425E

MBIB0416E

CYLINDER HEAD

EM-317

< REMOVAL AND INSTALLATION >

[K9K]

11. Check the valve protrusion using KV113B0040 (Mot. 251-01)

(Commercial service tool) or equivalent tool and KV113B0050
(Mot. 252-01) (Commercial service tool) or equivalent tool as
shown.

Camshaft Seal

• This engine can be fitted with two different types of seals.

Old and new seals are easily recognized.

The old rubber seal is installed with a spring (A) and has a “V”-
shaped sealing lip (B).

The new rubber seal has a flat sealing lip (C) and a protector (D)
which also assists in installing the seal to the engine.

Screw the shouldered rod of Tool KV113B0230 (Mot. 1632) onto
the stud of the camshaft.

Install the old seal on the camshaft.

Valve protrusion

−

0.07 to 0.07 mm (

−

0.0028 to

0.0028 in)

MBIB0426E

MBIB0428E

MBIB0429E

MBIB0430E

EM-318

< REMOVAL AND INSTALLATION >

[K9K]

CYLINDER HEAD

For the new seal, put the protector with the seal on the cam-
shaft, taking care not to touch the seal.

Install the cover (E) and the collar nut (F) of Tool KV113B0230
(Mot. 1632).

Screw the collar nut until the cover reaches the cylinder head.

Remove the nut, the cover, the protector and the shouldered
rod.

Install the camshaft pulley, and tighten the new nut as follows:

Tighten the new nut.

Turn the bolt 86 degrees clockwise (angle tightening) using
sprocket holder [SST: - (Mot. 1606-A)] (A).

MBIB0431E

MBIB0432E

MBIB0433E

: 30 N·m (3.1 kg-m, 22 ft-lb)

MBIB1931E

CYLINDER HEAD

EM-319

< REMOVAL AND INSTALLATION >

[K9K]

10. Install the vacuum pump with a new gasket

11. Install water outlet unit with a new gasket.

12. Install the exhaust manifold with new gasket. Tighten the bolts in

the numerical order as shown.

13. Install the EGR unit with new clips. Tighten the mounting bolts of the valve to a torque of 21 N·m (2.1 kg-

m, 15 ft-lb), then tighten the clips of the pipe using Tool KV113B0190 (Mot. 1567).

14. Install the air inlet pipe with a new seal.

15. Install the front engine slinger.

16. Clean the injector sockets and the injector bodies, as well as

their brackets using a lint-free cloth (use the wipes recom-
mended for this purpose) dipped in clean solvent.
Dry off using a different new wipe.
Replace the compression washer with a new washer.

17. Install the injectors (using the marks made during removal).

18. Install the glow plugs.

19. Install the rear engine slinger.

20. Install high pressure supply pump and related parts. Refer to

EM-294, "Exploded View"

EM-298,

"Exploded View"

INSTALLATION

• Install in the reverse order of removal paying attention to the following.

INSTALLATION OF THE CYLINDER HEAD

Position the pistons at mid-stroke.

Install the cylinder head gasket using the centering dowels of the cylinder block.

Tighten the cylinder head to the following procedure.

CAUTION:

All bolts must always be changed after removal. Never oil the new bolts.
NOTE:
Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to achieve
correct tightening of the bolts.

: 21 N·m (2.1 kg-m, 15 ft-lb)

: 11 N·m (1.1 kg-m, 8 ft-lb)

MBIB0411E

: 26 N·m (2.7 kg-m, 19 ft-lb)

JPBIA3039ZZ

: 28 N·m (2.9 kg-m, 21 ft-lb)

: 15 N·m (1.5 kg-m, 11 ft-lb)

MBIB0410E

EM-320

< REMOVAL AND INSTALLATION >

[K9K]

CYLINDER HEAD

Tighten all the bolts in the numerical order as shown.

Check that all the bolts are correctly tightened to 25 N·m (2.6 kg-
m, 18 ft-lb), then angle tightening of 245 to 265 degrees.

CAUTION:

• Use an angle wrench (special service tool) to check tight-

ening angle.

• Never retighten the cylinder head bolts after preforming

this procedure.

NOTE:
The gasket faces (cylinder head and rocker cover) must be clean, dry and free from grease (in par-
ticular, remove finger marks).

Lay four beads (A) of liquid gasket, with a diameter of 2 mm
(0.08 in).
• Use Genuine Liquid Gasket or equivalent.

Install the rocker cover, tighten the bolts in numerical order as
shown.

Put new seals on the pipe ends and install the turbocharger oil
return pipe.

Install the turbocharger.

Install the turbocharger oil supply pipe.

Tighten the bolts of the turbocharger oil return pipe.

: 25 N·m (2.6 kg-m, 18 ft-lb)

MBIB0323E

MBIB0502E

: Engine front

: 12 N·m (1.2 kg-m, 9 ft-lb)

JPBIA3119ZZ

: 26 N·m (2.7 kg-m, 19 ft-lb)

: 12 N·m (1.2 kg-m, 9 ft-lb)

MBIB0504E

CYLINDER HEAD

EM-321

< REMOVAL AND INSTALLATION >

[K9K]

10. Tighten the nut and the bolt of the turbocharger oil supply pipe

(A).

11. Install the oil vapor rebreathing pipe.

12. Install the new turbocharger air ducts.

13. Install the inner timing cover.
14. Install the timing tensioner.

Cleaning

INFOID:0000000006450006

• It is very important not to scratch the gasket faces of any aluminium components.
• Use suitable tool to dissolve any part of the seal which remains stuck to the metal surface.
• Apply the dissolving product to the part to be cleaned, wait approximately 10 minutes, then remove it using a

wooden spatula.

• Wear gloves while carrying out this operation.
• Do not allow this dissolving product to drip on to the paintwork.
• Great care should be taken when performing this operation, to prevent foreign objects from entering

the pipes taking oil under pressure to the camshafts (pipes in both the cylinder head and its cover)
and the oil return pipes.

• Failure to follow these instructions could lead to the blocking of the oilways, resulting in rapid and

serious damage to the engine.

Inspection

INFOID:0000000006450007

INSPECTION AFTER REMOVAL

GASKET FACE

• Inspect mating surface bow using a ruler and a set of shims.

• Test the cylinder head to detect possible cracks using the cylinder head test tools (comprising a tray and a kit

suited to the cylinder head, plug, sealing plate and blanking plate). The approval number of the cylinder
head test container (commercial service tool) is 664000.

CAMSHAFT END PLAY

NOTE:
Set the dial gauge to the cylinder head and inspect following dimensions:

: 23 N·m (2.3 kg-m, 17 ft-lb)

JPBIA3138ZZ

MBIB0400E

Maximum bow

: 0.05 mm (0.0020 in)

Outer diameter

: 18 mm (0.71 in)

Height

: 15 mm (0.59 in)

EM-322

< REMOVAL AND INSTALLATION >

[K9K]

CYLINDER HEAD

Install the camshaft.

Install the camshaft brackets (positioning them correctly with
bracket 1 on the flywheel end), then tighten the bolts to a torque
of 11 N·m (1.1 kg-m, 8 ft-lb).
Check the end play, which must be between 0.08 mm (0.0031
in) and 0.178 mm (0.0070 in).
Remove the camshaft brackets and the camshaft.

THICKNESS OF THE CYLINDER HEAD GASKET

• The thickness of the cylinder head gasket is measured at (A):

VALVE DIMENSIONS

VALVE SEAT

MBIB0420E

Thickness

: 0.75 - 0.81 mm (0.0295 - 0.0319 in)

MBIB0324E

Stem diameter:

Intake

: 5.969 - 5.985 mm (0.2350 - 0.2356 in)

Exhaust

: 5.955 - 5.971 mm (0.2344 - 0.2351 in)

Face angle:

Intake and ex-
haust

: 90

Head diameter:

Intake

: 33.38 - 33.62 mm (1.3142 - 1.3236 in)

Exhaust

: 28.88 - 29.12 mm (1.1370 - 1.1465 in)

Valve length:

Intake

: 100.73 - 101.17 mm (3.9657 - 3.9831 in)

Exhaust

: 100.53 - 100.97 mm (3.9579 - 3.9752 in)

Max. valve lift:

Intake

: 8.015 mm (0.3156 in)

Exhaust

: 8.595 mm (0.3384 in)

Protrusion of valves in relation to the cylinder head gasket face:

Intake and ex-
haust

−

0.7 to 0.7 mm (

−

0.028 to 0.028 in)

CYLINDER HEAD

EM-323

< REMOVAL AND INSTALLATION >

[K9K]

VALVE GUIDE

The intake and exhaust guides have valve stem seals which must be changed each time the valves are
removed.
It is imperative to fit the valve stem seals using Tool
KV113B0180 (Mot. 1511-01) (Commercial service tool) or equiv-
alent tool.
NOTE:
Do not lubricate the valve stem seals before fitting them.

Seat angle (

Intake
and ex-
haust

: 89

′

Contacting width (X):

Intake
and ex-
haust

: 1.8 mm (0.071 in)

Seat outer diameter (D):

Intake

: 34.444 - 34.460 mm (1.3561 - 1.3567 in)

Exhaust

: 30.034 - 30.050 mm (1.1824 - 1.1831 in)

Diameter of the housing in the cylinder head:

Intake

: 34.444 - 34.474 mm (1.3561 - 1.3572 in)

Exhaust

: 29.955 - 29.985 mm (1.1793 - 1.1805 in)

MBIB0327E

Length:

Intake and
exhaust

: 40.35 - 40.65 mm (1.5886 - 1.6004 in)

Guide outer diameter:

Standard

: 11.044 - 11.062 mm (0.4348 - 0.4355 in)

Guide inner diameter:

Intake and exhaust

Not ma-
chined

: 5.50 - 5.62 mm (0.2165 - 0.2213 in)

Machined*

: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

* This dimension is measured with the guide fitted in the cylinder head.

Diameter of the housing in the cylinder head:

Standard

: 10.9925 - 11.0075 mm (0.4328 - 0.4334 in)

MBIB0328E

EM-324

< REMOVAL AND INSTALLATION >

[K9K]

CYLINDER HEAD

VALVE SPRING

The valve springs are tapered (ensure the correct direction of fitting).

WARNING:

MBIB0329E

Angle of the intake and exhaust guides (in degrees)

Intake and exhaust

= 90

MBIB0330E

Position of the intake and exhaust valve guides

Intake

: A = 14 mm (0.55 in)

Exhaust

: A = 14.2 mm (0.559 in)

MBIB0331E

Free height:

: 43.31 mm (1.7051 in)

Length under a load of

230 N (23.5 kg, 51.7 lb)

: 33.80 mm (1.3307 in)

500 N (51.0 kg, 112.4 lb)

: 24.80 mm (0.9764 in)

Joined spires:

: 23.40 mm (0.9213 in)

Wire diameter:

: 3.45 mm (0.1358 in)

Inner diameter:

Bottom

: 18.78 - 18.82 mm
(0.7394 - 0.7409 in)

Top

: 13.90 - 14.30 mm
(0.5472 - 0.5630 in)

Outer diameter:

Bottom

: 25.50 - 25.90 mm
(1.0039 - 1.0197 in)

Top

: 20.8 - 21.2 mm (0.819
- 0.835 in)

MBIB0332E

CYLINDER HEAD

EM-325

< REMOVAL AND INSTALLATION >

[K9K]

This engine does not have any valve spring lower washers.

PISTON

CAMSHAFT

* As the intake opening retard is negative, the valve is opened after TDC.

** As the exhaust closing advance is negative, the valve is closed before TDC.

Piston outer diameter

: 34.965 - 34.985 mm (1.3766 - 1.3774 in)

Diameter of the housing in the cylinder head

: 35.00 - 35.04 mm (1.3780 - 1.3795 in)

End play

: 0.08 - 0.178 mm (0.0031 - 0.0070 in)

Number of bearings

: 6

Diameter of the camshaft bearings

On the camshaft:

Bearings 1, 2, 3, 4, 5

: 24.979 - 24.999 mm (0.9834 - 0.9842 in)

Bearing 6

: 27.979 - 27.999 mm (1.1015 - 1.1023 in)

On the cylinder head:

Bearings 1, 2, 3, 4, 5

: 25.04 - 25.06 mm (0.9858 - 0.9866 in)

Bearing 6

: 28.04 - 28.06 mm (1.1039 - 1.1047 in)

Timing diagram

Intake opening retard *

−

Intake closing retard

: 20

Exhaust opening advance

: 27

Exhaust closing advance **

−

Cylinder block TDC fixed mark

Flywheel TDC moving mark

Flywheel BDC moving mark

Intake Opening Retard

Exhaust Closing Advance

Intake Closing Retard

Exhaust Opening Advance

Direction of engine rotation (flywheel end).

MBIB0336E

EM-326

< UNIT REMOVAL AND INSTALLATION >

[K9K]

ENGINE ASSEMBLY

UNIT REMOVAL AND INSTALLATION

ENGINE ASSEMBLY

Exploded View

INFOID:0000000006450008

Removal and Installation

INFOID:0000000006450009

WARNING:

• Situate vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS

CATALOG.

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 main body 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 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-37, "Board-On Lift"

REMOVAL

Description of work

Engine torque rod

Engine mounting insulator

Engine mounting stay

Transaxle mounting stay

Engine mounting rear bracket

Transaxle torque rod

Transaxle mounting upper bracket

Transaxle mounting insulator

: Vehicle front

: N·m (kg-m, ft-lb)

JPBIA4803GB

ENGINE ASSEMBLY

EM-327

< UNIT REMOVAL AND INSTALLATION >

[K9K]

Remove engine and transaxle assembly from vehicle down ward. Separate engine and transaxle.
Preparation
1.

Remove the following parts.
• Battery ground cable.
• Engine undercover.
• LH/RH front wheel. Refer to

WT-7, "Exploded View"

• LH/RH fender protector. Refer to

EXT-22, "Exploded View"

Engine room

Drain engine coolant. Refer to

CO-62, "Draining"

CAUTION:

Perform when engine is cold.

Remove air cleaner case. Refer to

EM-280, "Exploded View"

Remove turbocharger air inlet pipe. Refer to

EM-280, "Exploded View"

Remove reservoir tank hoses. Refer to

CO-66, "Exploded View"

Remove radiator upper hose. Refer to

CO-66, "Exploded View"

Remove cooling fan shroud assembly. Refer to

CO-68, "Exploded View"

Remove alternator.

Remove vacuum hose. Refer to

EM-293, "Exploded View"

10. Disconnect heater hoses.

11. Disconnect engine room harness from the engine side and set it aside for easier work.

12. Disconnect transaxle side harness and clutch tube.
13. Disconnect shift cable and select cable. Refer to

TM-78, "Exploded View"

14. Disconnect all the body-side vacuum hoses and air hoses at engine side.

15. Disconnect fuel feed and return hoses, and plug it to prevent fuel from draining.
Vehicle underbody

16. Remove radiator lower hose. Refer to

CO-66, "Exploded View"

17. Disconnect thermo plunger connector and earth cable. Refer to

CO-72, "Exploded View"

18. Remove thermo plunger unit stay, and set thermo plunger unit aside for easier work.

19. Remove drive shaft lock pin and lock nut. Refer to

FAX-77, "Exploded View"

20. Remove strut lower bolts.
21. Remove drive shaft assembly RH and LH. Refer to

FAX-77, "Exploded View"

22. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to

avoid putting load on it.

23. Remove altarnator bracket.

24. Remove diesel particulate filter assembly. Refer to

EX-17, "Exploded View"

25. Remove engine rear mounting bracket.
Removal

26. Use a manual lift table caddy (commercial service tool) or equiv-

alently rigid tool such as a jack or trestle. Securely support bot-
tom of engine and transaxle.

CAUTION:

Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.

27. Remove RH and LH engine mounting bolts.

28. Remove engine and transaxle assembly from vehicle downward

by carefully operating supporting tools.

CAUTION:

• During the operation, make sure that no part interferes

with body side.

• Before and during this lifting, always check if any harnesses are left connected.
• During the removal operation, always be careful to prevent vehicle from falling off the lift due to

changes in the center of gravity.

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

MBIB1045E

EM-328

< UNIT REMOVAL AND INSTALLATION >

[K9K]

ENGINE ASSEMBLY

Separation Work

CAUTION:

During the operation, secure support the engine by placing a piece of wood under the engine oil pan,
transaxle oil pan and suspended the engine slinger by baby crane (movable hoist) etc.

29. Remove starter motor.
30. Separate engine and transaxle.

31. Lift with the hoist and separate the engine from the transaxle assembly.

INSTALLATION

Install in the reverse order of removal.
• Do not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
• When installation directions are specified, install parts according to the direction marks on them referring to

components illustration.

• Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.

Inspection

INFOID:0000000006450010

INSPECTION AFTER INSTALLATION

• Before starting engine check the levels of coolant, lubrications and working oils. If less than required quan-

tity, fill to the specified level.

• Before starting engine, bleed air from fuel piping. Refer to

FL-50, "Air Bleeding"

• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and

exhaust gas.

• Bleed air from passages in pipes and tubes of applicable lines.

ENGINE STAND SETTING

EM-329

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

UNIT DISASSEMBLY AND ASSEMBLY

ENGINE STAND SETTING

Preparing the engine to be on the stand

INFOID:0000000006450011

Before the engine is mounted on the engine sub-attachment, the engine's electrical harness must be removed
and the engine oil drained.

Remove the multifunction support.

Remove the coolant inlet pipe on the water pump.

Place the rods (A), (X), (Y) on the cylinder block.

MBIB0355E

MBIB0356E

MBIB0357E

EM-330

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

CYLINDER BLOCK

CYLINDER BLOCK

Disassembly and Assembly

INFOID:0000000006450012

PREPARING USED ENGINE

The engine should be cleaned and drained (oil and water).

Leave on the used engine or include in the return box:

• Oil filter
• Oil pressure switch
• Water pump
• Fuel injection pump
• Rail
• Injectors
• Glow plugs
• Oil level gauge
• Vacuum pump
• Flywheel

Remember to remove:

• All coolant pipes
• Exhaust manifold
• Alternator
• Power steering pump
• A/C compressor
• Alternator bracket
• Oil level sensor
• Cylinder head coolant outlet unit

The used engine should be secured to the base under the same conditions as the overhauled engine:

• Plastic plugs and covers fitted
• Cardboard cover over the assembly

DISASSEMBLY

REMOVING THE UPPER ENGINE

Remove the upper timing cover by unclipping the two tabs (A).

MLIA0004E

CYLINDER BLOCK

EM-331

< UNIT DISASSEMBLY AND ASSEMBLY >

[K9K]

Remove the lower timing cover by unclipping the three tabs (B)
and pulling out the plastic bolt (C).

Remove the cylinder head suspended mounting bracket and
high pressure pump position sensor.

Remove the TDC pin cap.

MBIB0390E

MBIB0391E

MBIB0392E

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