Juke F15 (2012 year). Service Repair Manual - part 182

EM-60

< UNIT REMOVAL AND INSTALLATION >

[MR16DDT ]

ENGINE ASSEMBLY

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

1.

Release fuel pressure. Refer to 

EC-140, "Work Procedure"

.

2.

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.

3.

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, 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"

.

• Radiator cooling fan assembly: Refer to

CO-20, "Exploded View"

.

• Exhaust front tube: Refer to 

EX-5, "Exploded View"

.

• Alternator: Refer to 

CHG-30, "MR16DDT : Exploded View"

.

Engine Room LH

1.

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.

2.

Disconnect fuel feed hose quick connector. Refer to 

EM-43, "Exploded View"

.

3.

Disconnect heater hoses. Refer to 

CO-26, "Exploded View"

.

4.

Disconnect control cable from transaxle. Refer to 

TM-273, "Exploded View"

.

5.

Remove EVAP hoses. Refer to 

EM-28, "Exploded View"

.

Engine Room RH

1.

Disconnect vacuum hose from intake manifold. Refer to 

EM-28, "Exploded View"

.

2.

Remove A/C compressor. Refer to 

HA-86, "Exploded View"

.

3.

Remove ground cable at engine side.

Vehicle Underbody

1.

Remove ground cable at transaxle side.

2.

Remove rear propeller shaft. Refer to 

DLN-121, "Exploded View"

.

3.

Remove drive shafts (RH and LH). Refer to 

FAX-21, "Exploded View"

.

ENGINE ASSEMBLY

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4.

Remove rear torque rod (1).

5.

Remove stabilizer connecting rod. Refer to 

FSU-16, "Exploded View"

.

6.

Rear front suspension member. Refer to 

FSU-18, "Exploded View"

.

7.

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-40, "Exploded

View"

.

Removal

1.

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.

2.

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

3.

Remove engine mounting bracket (LH).

4.

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

2

: Rear engine mounting bracket

: Vehicle front

JPBIA4417ZZ

PBIC3223J

: Vehicle front

JPBIA4419ZZ

EM-62

< UNIT REMOVAL AND INSTALLATION >

[MR16DDT ]

ENGINE ASSEMBLY

1.

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

2.

Remove starter motor. Refer to 

STR-27, "MR16DDT : Exploded View"

.

3.

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

TM-301, "Exploded View"

(CVT models).

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-59, "4WD : Exploded View"

.

4WD : Inspection

INFOID:0000000006337289

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:

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

: 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)

JPBIA4422ZZ

Items

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluid*

Level

Leakage

Level

Fuel

Leakage

Leakage

Leakage

Exhaust gases

—

Leakage

—

ENGINE STAND SETTING

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UNIT DISASSEMBLY AND ASSEMBLY

ENGINE STAND SETTING

Setting

INFOID:0000000006337290

NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc.
1.

Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. 

2.

Install engine to engine stand with the following procedure:

a.

Remove flywheel (M/T models) or drive plate (CVT models).
• Secure flywheel (M/T models) or drive plate (CVT models) (1)

with a stopper plate [SST: KV11105210 (J-44716)] (A), and
remove mounting bolts.

CAUTION:

• Never disassemble them.
• Never place them with signal plate facing down.
• When handling signal plate, take care not to damage or

scratch them. 

• Handle signal plate in a manner that prevents them from

becoming magnetized.

NOTE:
This figure shows CVT models as an example.

b.

Remove pilot converter (1) using pilot bushing puller [SST:
ST16610001 (J-23907)] (A) or suitable tool. (CVT models)
NOTE:
M/T models have no pilot bushing.

c.

Lift the engine with a hoist to install it onto widely use engine stand.

CAUTION:

• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large

enough for supporting the engine weight. 

• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-

tial risk of overturning stand.

- Intake manifold: Refer to 

EM-28, "Exploded View"

. 

- catalyst convertor: Refer to 

EM-33, "2WD : Exploded View"

 (2WD models) or 

EM-34, "4WD : Exploded

View"

 (4WD models).

- Rocker cover: Refer to 

EM-53, "Exploded View"

.

NOTE:

JPBIA4425ZZ

PBIC3229J

EM-64

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR16DDT ]

ENGINE STAND SETTING

The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel (M/T
models) or drive plate (CVT models) removed.

CAUTION:

Before removing the hanging chains, check the engine
stand is stable and there is no risk of overturning.

3.

Drain engine oil. Refer to 

LU-9, "Draining"

.

CAUTION:

Be sure to clean drain plug and install with new drain plug washer.

4.

Drain engine coolant by removing water drain plug (1) from
inside of the engine. 

Use Genuine Liquid Gasket or equivalent. 

PBIC3227J

: Engine front

Tightening torque

: Refer to 

EM-104, "Disassembly 

and Assembly"

.

PBIC3228J

ENGINE UNIT

EM-65

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ENGINE UNIT

Disassembly

INFOID:0000000006337291

1.

Remove intake manifold. Refer to 

EM-28, "Exploded View"

.

2.

Remove catalyst convertor. Refer to 

EM-33, "2WD : Exploded View"

 (2WD models) or 

EM-34, "4WD :

Exploded View"

 (4WD models).

3.

Remove turbocharger. Refer to 

EM-36, "Exploded View"

.

4.

Remove exhaust manifold. Refer to 

EM-38, "Exploded View"

.

5.

Remove oil pan (lower). Refer to 

EM-99, "Exploded View"

.

6.

Remove ignition coil, spark plug, and rocker cover. Refer to 

EM-23, "Exploded View"

.

7.

Remove fuel injector and fuel tube. Refer to 

EM-47, "Exploded View"

.

8.

Remove timing chain. Refer to 

EM-67, "Exploded View"

.

9.

Remove camshaft. Refer to 

EM-78, "Exploded View"

.

10. Remove water inlet. Refer to 

CO-24, "Exploded View"

.

11. Remove water outlet. Refer to 

CO-26, "Exploded View"

.

12. Remove cylinder head. Refer to 

EM-90, "Exploded View"

.

Assembly

INFOID:0000000006337292

Assemble in the reverse order of disassembly.

EM-66

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR16DDT ]

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY

Exploded View

INFOID:0000000006337247

Removal and Installation

INFOID:0000000006337248

Removal

1.

Loosen mounting bolt and remove drive belt auto-tensioner. 

Installation

Install in the reverse order of removal.

CAUTION:

When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.

1.

Front cover

2.

Drive belt auto-tensioner

 : N·m (kg-m, ft-lb)

JPBIA4304GB

TIMING CHAIN

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TIMING CHAIN

Exploded View

INFOID:0000000006337274

1.

Timing chain slack guide

2.

Timing chain tensioner

3.

Timing chain

4.

Oil pump drive chain

5.

Crankshaft sprocket

6.

Crankshaft key

7.

Oil pump sprocket

8.

Front cover

9.

O-ring

10. O-ring

11. Oil control valve cover

12. O-ring

13. Oil control valve (EXH)

14. Oil control valve (INT)

15. Crankshaft pulley bolt

16. Crankshaft pulley

17. Front oil seal

18. Oil pump drive chain tensioner

19. O-ring

20. Timing chain tension guide

21. Camshaft spsocket (INT)

JPBIA4313GB

EM-68

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR16DDT ]

TIMING CHAIN

Removal and Installation

INFOID:0000000006337275

REMOVAL

CAUTION:

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

1.

Drain engine oil. Refer to 

LU-9, "Draining"

.

CAUTION:

Perform this step when engine is cold.

2.

Remove the following parts:
• Intake manifold: Refer to 

EM-28, "Exploded View"

.

• Rocker cover: Refer to 

EM-23, "Exploded View"

.

3.

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

a.

Rotate crankshaft pulley (1) clockwise and align TDC mark (no
paint) (B) to timing indicator (A) on front cover. 

b.

At the same time, check that the cam noses of the No. 1 cylinder
are located (

) as shown in the figure.

• If not, rotate crankshaft pulley one revolution (360 degrees)

and align as shown in the figure.

4.

Remove crankshaft pulley with the following procedure:

22. Camshaft sprocket (EXH)

23. O-ring

A.

Tightening must be done following 
the installation procedure.
Refer to 

EM-68

 : N·m (kg-m, ft-lb)

 : N·m (kg-m, in-lb)

 : Always replace after every disassembly.

 : Should be lubricated with oil.

 : Sealing point

C

: White paint mark (Not use for service)

PBIC3960E

1

: Camshaft (INT)

2

: Camshaft (EXH)

: Engine front

JPBIA4347ZZ

TIMING CHAIN

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a.

Fix crankshaft pulley (1) with a pulley holder (commercial ser-
vice tool) (A), loosen crankshaft pulley bolt, and locate bolt seat-
ing surface at 10 mm (0.39 in) from its original position.

CAUTION:

Never remove the crankshaft pulley bolt as they will be
used as a supporting point for the pulley puller [SST:
KV11103000 (

—

)].

b.

Attach a pulley puller [SST: KV11103000 (

—

)] (A) in the M6

thread hole on crankshaft pulley (1), and remove crankshaft pul-
ley. 

5.

Remove oil pan (lower). Refer to 

EM-99, "Exploded View"

.

NOTE:
If crankshaft sprocket and oil pump drive component are not removed, this step is unnecessary.

6.

Remove intake valve timing control solenoid valve.

7.

Remove drive belt auto-tensioner. Refer to 

EM-66, "Exploded View"

.

8.

Remove front cover with the following procedure:

a.

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

PBIC3961E

PBIC3962E

JPBIA4393ZZ

EM-70

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR16DDT ]

TIMING CHAIN

b.

Cut liquid gasket by prying the position (

) shown in the figure,

and then remove the front cover.

CAUTION:

• Be careful not to damage the mating surface.
• A more adhesive liquid gasket is applied compared to pre-

vious types when shipped, so it should not be forced off
the position not specified.

9.

Remove front oil seal from front cover. 

CAUTION:

Be careful not to damage front cover.
• Lift up front oil seal using a screwdriver.

10. Remove timing chain tensioner with the following procedure:

a.

Insert a wire (A) (e.g. clip) into the top groove with the timing
chain tensioner plunger pressed. 
NOTE:
Timing chain tensioner plunger is securely fixed by inserting a
wire (e.g. clip).

b.

Remove timing chain tensioner (1).

JPBIA4394ZZ

JPBIA4395ZZ

TIMING CHAIN

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11. Remove slack guide (2), tension guide (3) and timing chain (1).

CAUTION:

Never rotate each crankshaft and camshaft individually
while timing chain is removed. It causes interference
between valve and piston.
NOTE:
If timing chain is difficult to remove, remove camshaft sprocket
(EXH) first to remove timing chain.

12. Remove crankshaft sprocket and oil pump drive component with the following procedure:
a.

Push oil pump drive chain tensioner (1) in the direction show in
the figure (A).

b.

Insert a stopper pin (A) into the body hole (B).

c.

Remove oil pump chain tensioner.
• When the holes on lever and tensioner body cannot be

alirned, align these holes by slightly moving the oil pump chain
tensioner slack guide.

d.

Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A),
and then loosen the oil pump sprocket bolt and remove it.

CAUTION:

• Secure the oil pump shaft with the WAF part.
• Never loosen the oil pump sprocket bolt by tightening the

oil pump drive chain.

JPBIA4396ZZ

JPBIA4397ZZ

1

: Oil pan (upper)

: Engine front

JPBIA4398ZZ

EM-72

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR16DDT ]

TIMING CHAIN

13. Remove tension guide (front cover side) from front cover, if necessary.

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.

*: There are two outer grooves in camshaft sprocket (EXH). The wider one is a matching mark.

1.

Check that crankshaft key points straight up.

2.

If the tension guide (front cover side) is removed, install it to the front cover.

CAUTION:

Check the joint condition by sound or feeling.

3.

Install crankshaft sprocket (2), oil pump sprocket (3), and oil
pump drive chain (1).

• Install it by aligning matching marks on each sprockets and oil

pump drive chain. 

• If these matching marks are not aligned, rotate the oil pump

shaft slightly to correct the position.

CAUTION:

Check matching mark position of each sprockets after
installing the oil pump drive chain.

1

: Timing chain 

2

: Camshaft sprocket (EXH)

3

: Slack guide

4

: Timing chain tensioner

5

: Crankshaft sprocket

6

: Oil pump drive chain

7

: Oil pump sprocket

8

: Oil pump drive chain tensioner

9

: Tension guide

10

: Camshaft sprocket (INT)

A

: Matching mark (dark blue link)

B

: Matching mark (outer groove*)

C

: Crankshaft key position (straight up)

D

: Matching mark (stamping)

E

: Matching mark (white link)

F

: Matching mark (yellow link)

G

: Matching mark (outer groove)

A

: Matching mark (stamping)

B

: Matching mark (yellow link)

C

: Matching mark (dark blue link)

JPBIA4399ZZ

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TIMING CHAIN

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4.

Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A),
and then tighten the oil pump shaft sprocket bolt.

CAUTION:

• Secure the oil pump shaft with the WAF part.
• Never loosen the oil pump shaft sprocket bolt by tighten-

ing the oil pump drive chain.

5.

Install oil pump 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 oil

pump chain tensioner.

• Check matching mark position of oil pump drive chain and

each sprockets again.

1

: Oil pan (upper)

: Engine front

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EM-74

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR16DDT ]

TIMING CHAIN

6.

Align the matching marks of each sprockets with the matching
marks of timing chain.

*: There are 2 outer grooves in camshaft sprocket (EXH). The wider one is a
matching mark.

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

slightly by holding the hexagonal portion to correct the posi-
tion.

CAUTION:

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

7.

Install the slack guide (2) and the tension guide (3).

8.

Install timing chain tensioner.
• Fix the plunger at the most compressed position using a stopper pin, and then install it.
• Securely pull out the stopper pin after installing the timing chain tensioner.

9.

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

10. Install front oil seal. Refer to 

EM-88, "FRONT OIL SEAL : Removal and Installation"

.

11. Install front cover with the following procedure:

a.

Install new O-ring to cylinder block. 

CAUTION:

Never misalign O-ring.

1

: Camshaft sprocket (EXH)

2

: Camshaft sprocket (INT)

3

: Timing chain

A

: Matching mark (dark blue link)

B

: Matching mark (outer groove*)

C

: Matching mark (outer groove)

D

: Matching mark (white link)

E

: Matching mark (stamping)

JPBIA4402ZZ

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: Timing chain

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TIMING CHAIN

EM-75

< UNIT DISASSEMBLY AND ASSEMBLY >

[MR16DDT ]

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b.

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

Use Genuine Liquid Gasket or equivalent.

c.

Check that matching marks of timing chain and each sprockets are still aligned. Then install front cover.

CAUTION:

• Check O-ring on cylinder block is correctly installed.
• Be careful not to damage front oil seal by interference with front end of crankshaft.

d.

Install front cover, and tighten mounting bolts in numerical order
as shown in the figure.
• Refer to the following for the installation position of bolts.

CAUTION:

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

e.

After all bolts are tightened, retighten them to specified torque in
numerical order as shown in the figure.

CAUTION:

Be sure to wipe off any excessive liquid gasket leaking.

12. Install crankshaft pulley with the following procedure: 
a.

When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).

CAUTION:

Never damage front oil seal lip section.

1

: Cylinder head

2

: Front cover

A

: Liquid gasket application area

b

: 4.0 - 5.6 mm (0.157 - 0.220 in)

c

: 

φ

3.4 - 4.4 mm (0.134 - 0.173 in)

: Engine outside

JPBIA4403ZZ

M6 bolt

: No. 1

M10 bolts

: No. 6, 7, 10, 13, 21

M12 bolts

: No. 2, 4, 8, 11

M8 bolts

: Except the above

JPBIA4393ZZ