Nissan Juke (2012 year). Service Repair Manual

EM-42

< 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.

Remove gasket.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

INSTALLATION

Install gasket to cylinder head as shown in the figure.

Install exhaust manifold with the following procedure:

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.

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

EM-136, "Exhaust Manifold"

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Revision: 2011 October

2012 JUKE

OIL PAN (LOWER)

EM-43

< REMOVAL AND INSTALLATION >

[MR16DDT ]

OIL PAN (LOWER)

Exploded View

INFOID:0000000007577449

O-ring

Oil pan (upper)

Oil level gauge guide

O-ring

Oil level gauge

Oil pump drive chain

Crankshaft sprocket

Oil pump sprocket

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

Refer to

LU-10

To thermostat hosing

To thermostat housing (M/T models)
To CVT oil warmer (CVT models)

Oil pan side

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

: Sealing point

JPBIA4875GB

Revision: 2011 October

2012 JUKE

EM-44

< REMOVAL AND INSTALLATION >

[MR16DDT ]

OIL PAN (LOWER)

Removal and Installation

INFOID:0000000007577450

REMOVAL

Drain engine oil. Refer to

LU-8, "Draining"

Remove oil pan (lower) with the following procedure:

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

NOTE:
Disregard the numerical order No.7 and No.11 in removal.

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.

Slide the seal cutter [SST: KV10111100 (J-37228)] by tapping on
the side of tool with a hammer.

Remove oil pan (lower).

INSTALLATION

CAUTION:

Do not reuse drain plug washer.

Install oil pan (lower) as follows:

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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Revision: 2011 October

2012 JUKE

OIL PAN (LOWER)

EM-45

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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

GI-

CAUTION:

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

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.

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

EM-106, "Exploded View"

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

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

LU-7, "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-7, "Inspection"

: Oil pan (lower)

: 7.5 - 9.5 mm (0.295 - 0.374 in)

4.0 - 5.0 mm (0.157 - 0.197 in)

: Engine outside

: Engine front

JPBIA4367ZZ

: Engine front

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Revision: 2011 October

2012 JUKE

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:

• Be sure to read

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

fire extinguisher.

High pressure fuel pump insulator

High pressure fuel pump

O-ring

High pressure fuel pump lifter

Fuel rail connector

Fuel tube

Bracket

Fuel pump connector protector

Fuel feed hose

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.

JSBIA1672GB

Revision: 2011 October

2012 JUKE

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

EM-47

< REMOVAL AND INSTALLATION >

[MR16DDT ]

• 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

EC-136, "Work Procedure"

Remove engine cover. Refer to

EM-24, "Exploded View"

Remove fuel pump connector protector, and remove high pressure fuel pump insulator.

Disconnect quick connector (A) with the following procedure.

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

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.

Remove intake manifold. Refer to

EM-28, "Removal and Installation"

Remove fuel tube.

Remove fuel rail connector.

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Retainer color

: Red

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Revision: 2011 October

2012 JUKE

EM-48

< REMOVAL AND INSTALLATION >

[MR16DDT ]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

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.

Install high pressure fuel pump according to the following procedure.

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

Aim pump cam at the BDC area (arrow position).

NOTE:
For BDC area, anywhere within 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:

• 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.

Install high pressure fuel pump lifter.

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

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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Revision: 2011 October

2012 JUKE

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

EM-49

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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.

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, and no
damage on them.

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 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.

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.

: High pressure fuel pump

JSBIA1673ZZ

: Lock position

: Unlock position

JPBIA4381ZZ

: O-ring

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Revision: 2011 October

2012 JUKE

EM-50

< REMOVAL AND INSTALLATION >

[MR16DDT ]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

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.

Temporarily tighten bolt (4) until the seat of bracket is seated.

Tighten flare nut (A) and (B) in alphabetical order.

CAUTION:

Always fit the tool completely with the nut.

Tighten bolt (4).

Install in the reverse order of removal after this step.

Inspection

INFOID:0000000007577454

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.

: High pressure fuel pump

: Fuel rail connector

JPBIA5808ZZ

Revision: 2011 October

2012 JUKE

FUEL INJECTOR AND FUEL TUBE

EM-51

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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:

Holder

Seal ring (white)

Backup ring

O-ring (blue)

Fuel injector

Stud bolt

Fuel rail

Fuel rail insulator (united type)

Adaptor cover (separated type)

10. Fuel rail insulator (separated type)

11. Fuel rail cover

12. Fuel pressure sensor

13. Gasket

To fuel rail connector and fuel tube.
Refer to

EM-46

Comply with the assembly procedure
when tightening. Refer to

EM-51

: 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

• Be sure to read

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

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-136, "Work Procedure"

Remove front bumper. Refer to

EXT-11, "Exploded View"

Remove charge air cooler. Refer to

EM-30, "Exploded View"

Remove oil level gauge. Refer to

EM-43, "Exploded View"

Remove intake manifold. Refer to

EM-27, "Exploded View"

Remove alternator. Refer to

CHG-22, "Exploded View"

Remove oil level gauge guide. Refer to

EM-43, "Exploded View"

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).

Remove fuel tube and fuel rail connector. Refer to

EM-46, "Exploded View"

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.

Remove injector holder.

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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Revision: 2011 October

2012 JUKE

FUEL INJECTOR AND FUEL TUBE

EM-53

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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

(—)] (A) to groove portion (C) of injector

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

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

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

JSBIA0343ZZ

JPBIA4383ZZ

JPBIA4384ZZ

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Revision: 2011 October

2012 JUKE

EM-54

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL INJECTOR AND FUEL TUBE

INSTALLATION

CAUTION:

Do not reuse O-rings.

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:

JPBIA4386ZZ

JSBIA0348ZZ

JSBIA0350ZZ

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Revision: 2011 October

2012 JUKE

FUEL INJECTOR AND FUEL TUBE

EM-55

< REMOVAL AND INSTALLATION >

[MR16DDT ]

• 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.

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

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.

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.

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 fuel pressure sensor, if removed.

JPBIA3864ZZ

: O-ring (blue)

: Backup ring

JPBIA4387ZZ

: 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

Revision: 2011 October

2012 JUKE

EM-56

< REMOVAL AND INSTALLATION >

[MR16DDT ]

FUEL INJECTOR AND FUEL TUBE

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.

Install in the reverse order of removal after this step.

Inspection

INFOID:0000000007577457

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.

Revision: 2011 October

2012 JUKE

IGNITION COIL, SPARK PLUG AND ROCKER COVER

EM-57

< REMOVAL AND INSTALLATION >

[MR16DDT ]

IGNITION COIL, SPARK PLUG AND ROCKER COVER

Exploded View

INFOID:0000000007577458

Removal and Installation

INFOID:0000000007577459

REMOVAL

Drain engine coolant. Refer to

CO-8, "Draining"

Remove engine cover. Refer to

EM-24, "Exploded View"

Remove air inlet tube assembly. Refer to

EM-30, "Exploded View"

Remove PCV hose.

Remove rocker cover protector.

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

CAUTION:

• Never drop or shock 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 intake manifold

Comply with the assembly procedure
when tightning. Refer to

EM-57

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

Nissan Juke (2012 year). Service Repair Manual - part 110