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Nissan Juke (2016 year). Service Repair Manual - part 331

EM-204

< REMOVAL AND INSTALLATION >

[MR EXCEPT FOR NISMO RS MODELS]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

• 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.

1. Release fuel pressure. Refer to

EC-771, "Work Procedure"

2. Remove the engine cover. Refer to

EM-191, "Removal and Installation"

3. Remove the high-pressure fuel pump connector protector and the high-pressure fuel pump insulator.
4. Follow the procedure below and disconnect the quick connector

(A).

a. Disconnect the hose clamp bracket (2) from the fuel feed hose

(1).

b. Follow the procedure below and disconnect the fuel feed connector from the high-pressure fuel pump.

1. Expand the two engaged retainer tabs in direction (A) to dis-

engage them.

2. Press the retainer up in direction (B) to the point as shown

by (C).

CAUTION:

Never remove the retainer completely.

3. Disconnect the fuel feed hose.

CAUTION:

Grasp part (D) as shown in the figure, and pull it out.

NOTE:

If the fuel feed hose connection is stuck, grasp the pipe,

push/pull it back and forth so that the hose moves, and dis-

connect it.

CAUTION:

• Keep removed parts away from flame and high-tempera-

ture locations.

• Never allow removed parts to contact battery fluid or

other acids.

• When removing and installing, be careful that the fuel

feed hose and quick connector are not bent or twisted.

• Because fuel leakage occurs, prepare a tray, shop cloth,

and other items in advance.

• Never pull in a lateral direction. The O-ring inside 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.

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Retainer color

: Red

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Revision: November 2015

2016 JUKE

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

EM-205

< REMOVAL AND INSTALLATION >

[MR EXCEPT FOR NISMO RS MODELS]

5. Remove intake manifold. Refer to

EM-197, "Removal and Installation"

6. Disconnect the high-pressure fuel tube.
7. Note the following and remove the high-pressure fuel pump (1)

and high-pressure fuel pump lifter.

CAUTION:

For preventing damage to the high-pressure fuel pump and

camshaft bracket, loosen the bolts (A) alternately one turn

at a time until the reaction force applied to the bolts (A) by

the high-pressure fuel pump disappears.

INSTALLATION

CAUTION:

Because there is a risk of part damage caused by abnormally generated pressure or uneven weight, be

sure to observe the installation procedure.

1. Follow the procedure below and install the high-pressure fuel pump.
a. Turn the crankshaft pulley to the TDC position.
b. Check that the flat surface from the high-pressure fuel pump

mounting part (

) to the high-pressure fuel pump drive cam is

parallel to the high-pressure fuel pump mounting surface (when

the cam is at the lowest position).

NOTE:

• When the piston is at TDC, one of the flat surfaces of the high-

pressure fuel pump drive cam (

) is parallel to the high-pres-

sure fuel pump installation surface (when the cam is at the

lowest position).

c. Note the following items, and install a new O-ring onto the high-pressure fuel pump.

CAUTION:

• Handle O-ring with bare hands. (Never wear gloves.)

• Lubricate O-ring with engine oil (low viscosity oil such as 5W

−

30).

• Never clean O-ring using solvent.

• Check that the O-ring and its mating part are free of foreign material.

• When installing O-ring, never scratch it with tool or fingernails. Never twist or stretch the O-ring.

• Insert O-ring straight into the high-pressure fuel pump. Never decenter or twist it.

d. Reinstall the high-pressure fuel pump lifter.
e. Follow the procedure below and install the high-pressure fuel pump.
i.

Apply engine oil to the high-pressure fuel pump mounting surface on the camshaft bracket and to the O-

ring.

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: Camshaft (EXH)

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Revision: November 2015

2016 JUKE

EM-206

< REMOVAL AND INSTALLATION >

[MR EXCEPT FOR NISMO RS MODELS]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

ii.

Temporarily tighten the bolts (A) by hand, and then tighten the

bolts (A) alternately one rotation at a time until the high-pressure

fuel pump flange (1) contacts the camshaft bracket.

iii. Tighten the bolts (A) to the specified torque.

2. Follow the procedure below and install the fuel feed hose.
a. Check the fuel tube and quick connector for damage or foreign material.
b. Check that the axis is lined up when inserting the quick connector into the fuel tube.
c.

Insert the retainer until a “click” sound is heard, and check that

the retainer is securely installed. Pull the quick connector by

hand and check that it is locked.

CAUTION:

If the retainer cannot be inserted smoothly, the quick con-

nector may not be connected correctly. Remove the quick

connector and then check the connection of quick connec-

tor again.

d. Secure fuel feed hose to clamp.
3. Follow the procedure below and install the high-pressure fuel tube.

CAUTION:

• Never reuse the high-pressure fuel hose. Always use a new one.

• If scratches or damage on the end of the high-pressure fuel tube are present, never use it.

• Always tighten in the correct order to the specified tightening torque.

a. Apply new engine oil to high-pressure fuel tube flare nipple (A)

and flare nuts (B),(C).

CAUTION:

Check that there is no foreign material on the high-pressure

fuel tube flare nipple and flare nuts.

b. Temporarily tighten until the high-pressure fuel tube (3) flare

nuts (B) and (C) contact the seat.

CAUTION:

When temporarily tightening the flare nuts, insert them so that they are aligned with the center of

the pipe.

Tighten the high-pressure fuel tube bracket mounting bolt (4) to the specified torque.

d. Tighten flare nuts to the specified torque in the order of (B) and (C).

CAUTION:

Before tightening, check that the tool is attached at a 90

angle to the flare nut when working.

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: Engaged condition

: Not engaged condi-
tion

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: High-pressure fuel pump

: Fuel rail

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

: 36.0 N·m (3.7 kg-m, 27 ft-lb)

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Revision: November 2015

2016 JUKE

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

EM-207

< REMOVAL AND INSTALLATION >

[MR EXCEPT FOR NISMO RS MODELS]

e. Again tighten flare nuts to the specified torque in the order of (B) and (C).

CAUTION:

Before tightening, check that the tool is attached at a 90

angle to the flare nut when working.

4. Note the following and install the removed parts in the reverse order of removal.

Inspection

INFOID:0000000012197395

INSPECTION AFTER INSTALLATION

Fuel Leakage Check

Check for fuel leakage according to the following procedure.
1. Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel

leakage at the locations where parts are removed and reinstalled.

NOTE:

Use a mirror or other means to check locations which cannot be seen directly.

2. Start the engine, increase the engine speed and again check for fuel leakage at the locations where parts

are removed and reinstalled.

CAUTION:

Be careful of burns when checking.

: 36.0 N·m (3.7 kg-m, 27 ft-lb)

Revision: November 2015

2016 JUKE

EM-208

< REMOVAL AND INSTALLATION >

[MR EXCEPT FOR NISMO RS MODELS]

FUEL INJECTOR

FUEL INJECTOR

Exploded View

INFOID:0000000012197396

CAUTION:

Never disassemble or remove components beyond the configuration shown in the figure.

Removal and Installation

INFOID:0000000012197397

WARNING:

• Be sure to read

EM-153, "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.

Injector holder

Seal ring (white)

Backup ring

O-ring (blue)

Fuel injector

Stud bolt

Fuel rail

Fuel rail insulator

Fuel rail cover

10. Gasket

11. Fuel rail pressure sensor

To fuel tube

Comply with the assembly procedure
when tightening.

EM-208

: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Should be lubricated with oil.

: Indicates that the parts is connected at points with same symbols in actual vehicle.

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Revision: November 2015

2016 JUKE

FUEL INJECTOR

EM-209

< REMOVAL AND INSTALLATION >

[MR EXCEPT FOR NISMO RS MODELS]

• To avoid the danger of being scalded, never drain engine coolant when engine is hot.

REMOVAL

1. Release fuel pressure. Refer to

EC-771, "Work Procedure"

2. Remove the front bumper. Refer to

EXT-17, "Removal and Installation"

3. Remove the charge air rcooler. Refer to

EM-194, "Removal and Installation"

4. Remove the oil level gauge.
5. Remove the intake manifold. Refer to

EM-197, "Removal and Installation"

6. Remove the alternator. Refer to

CHG-33, "MR16DDT : Removal and Installation"

7. Remove the oil level gauge guide. Refer to

EM-282, "Exploded View"

8. Remove the fuel rail cover and fuel rail insulator.
9. Remove the fuel tube. Refer to

EM-203, "Exploded View"

CAUTION:

Because fuel leakage occurs, prepare a tray, shop cloth, and other items in advance.

10. Disconnect the fuel rail pressure sensor harness connector.
11. Disconnect the fuel injector harness connector.
12. Remove the fuel rail pressure sensor if necessary.
13. Remove the fuel rail.

• Loosen mounting bolts in the reverse order of the numerical

order shown in the figure, and remove the fuel rail.

CAUTION:

• Be careful that no parts interfere with the fuel injectors.

• Because fuel leakage occurs, prepare a tray, shop cloth,

and other items in advance.

14. Follow the procedure below and remove the fuel injector from the fuel tube.

CAUTION:

• Be careful of leakage of fuel remaining in fuel tube.

• Never damage the nozzle of fuel injector.

• Never subject parts to impact by dropping or hitting.

• Never disassemble or adjust. (Disassembly and adjustment of this part is prohibited.)

a. Remove the injector holder.
b. Install the injector remover [SST: KV10119600 ( — )] (A) with the

slit (B) aligned with the fuel injector connector.

: Engine front

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Revision: November 2015

2016 JUKE

EM-210

< REMOVAL AND INSTALLATION >

[MR EXCEPT FOR NISMO RS MODELS]

FUEL INJECTOR

• Insert the tab (B) of the injector remover [SST: KV10119600 (

— )] (A) into the fuel injector groove (C).

Press the body of the injector remover [SST: KV10119600 ( — )]

(A) until it contacts the cylinder head.

d. Tighten the injector remover [SST: KV10119600 ( — )] clock-

wise, and remove injector from cylinder head.

e. Pinch the seal ring (1) and cut it off. Never scratch the fuel injec-

tor.

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Revision: November 2015

2016 JUKE

FUEL INJECTOR

EM-211

< REMOVAL AND INSTALLATION >

[MR EXCEPT FOR NISMO RS MODELS]

INSTALLATION

1. Follow the procedure below and install the seal ring onto the fuel injector.

CAUTION:

• Handle the O-ring with bare hands. (Never wear gloves when handling O-ring.)

• Never apply engine oil to the seal ring.

• Never use solvents or similar substances to clean the seal ring.

a. Install the injector seal drift [SST: KV101197S0 ( — )] (A) onto

the fuel injector (1).

b. Set the seal ring (1) onto the injector seal drift [SST:

KV101197S0 ( — )] (A).

c. Install the seal ring (1) set in step 2 by inserting it straight into

the fuel injector as shown in the figure.

CAUTION:

When inserting the seal ring, never insert it further than the

groove portion of the fuel injector.

d. After installing the seal ring onto the fuel injector, install the

injector seal drift [SST: KV101197S0 ( — )] (A) onto the fuel

injector as shown in the figure. Turn it left and right by 90

at a

time until it contacts the seal ring to settle the seal ring in place.

NOTE:

For correcting any elongation of the seal ring that occurs when

the injector seal drift is installed, use the drift so that the seal ring

is pressed and contracted.

2. Note the following points and install the O-ring and backup ring to the fuel injector.

CAUTION:

• Be sure to handle the O-ring with bare hands. (Never wear gloves.)

• Apply engine oil to the O-ring.

• Never use solvents or similar substances when cleaning the O-ring seal.

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Revision: November 2015

2016 JUKE

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