Juke F15 (2012 year). Service Repair Manual

EM-220

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

ENGINE STAND SETTING

• Use the engine stand that has a load capacity [approximately 150 kg (331 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-163, "Exploded View"

- Exhaust manifold: Refer to

EM-166, "Removal and Installation"

- Rocker cover: Refer to

EM-178, "Exploded View"

NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel
removed.

CAUTION:

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

Drain engine oil. Refer to

LU-26, "Draining"

CAUTION:

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

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-227, "Exploded

View"

PBIC3742E

ENGINE UNIT

EM-221

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

ENGINE UNIT

Disassembly

INFOID:0000000006449930

Remove intake manifold. Refer to

EM-163, "Exploded View"

Remove exhaust manifold. Refer to

EM-166, "Exploded View"

Remove oil pan (lower). Refer to

EM-169, "Exploded View"

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

EM-178, "Exploded View"

Remove fuel injector and fuel tube. Refer to

EM-173, "Exploded View"

Remove front cover and timing chain. Refer to

EM-181, "Exploded View"

Remove camshaft. Refer to

EM-191, "Exploded View"

Remove cylinder head. Refer to

EM-208, "Exploded View"

Assembly

INFOID:0000000006449931

Assemble in the reverse order of disassembly.

EM-222

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

OIL PAN (UPPER)

OIL PAN (UPPER)

Exploded View

INFOID:0000000006449932

With Oil Cooler

JPBIA4743GB

Rear oil seal

O-ring

Oil pan (upper)

Oil pump chain tensioner (for oil
pump drive chain)

Oil pump drive chain

Crankshaft sprocket

Oil pump sprocket

Oil pump

O-ring

10. O-ring

11.

Oil pan (lower)

12. Oil pan drain plug

13. Drain plug washer

14. Oil level sensor

15. Relief valve

16. Connector bolt

17. Oil filter

18. Oil cooler

19. O-ring

Refer to

EM-182

Refer to

LU-28

Oil pan (lower) side

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Sealing point

: Should be lubricated with oil.

OIL PAN (UPPER)

EM-223

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

With Out Oil Cooler

Removal and Installation

INFOID:0000000006449933

NOTE:
The oil strainer and oil pump are included in the oil pan (upper). Individual disassembly is prohibited.

REMOVAL

Remove the oil pan (lower). Refer to

EM-169, "Exploded View"

Remove oil pump sprocket and crankshaft sprocket together with oil pump drive chain. Refer to

EM-181,

"Exploded View"

Remove oil pan (upper) with the following procedure.

JPBIA4092GB

Rear oil seal

O-ring

Oil pan (upper)

Oil pump chain tensioner (for oil
pump drive chain)

Oil pump drive chain

Crankshaft key

Crankshaft sprocket

Oil pump sprocket

Oil pump

10. O-ring

11.

O-ring

12. Oil pan drain plug

13. Drain plug washer

14. Oil pan (lower)

15. Oil filter

16. Oil filter stud bolt

Refer to

EM-182

Refer to

LU-28

Oil pan (lower) side

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Sealing point

: Should be lubricated with oil.

EM-224

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

OIL PAN (UPPER)

Loosen oil pan (upper) mounting bolts in the reverse of the order
as shown in the figure.

Insert a flat-bladed offset screwdriver into the arrow (

) in the

figure and open up a crack between the oil pan (upper) cylinder
block.

Insert the seal cutter [SST: KV10111100] between the oil pan
(upper) and cylinder block. Slide seal cutter by tapping on the
side of tool with a hammer.

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 using a screwdriver, etc. outside the
indicated location.

• Never remove oil pump and oil strainer from oil pan (upper).

Remove rear oil seal from crankshaft.

INSTALLATION

Install the oil pan (upper) in the following procedure:

Use scraper to remove old liquid gasket from mating surfaces.
• Also remove the old liquid gasket from mating surface of cylinder block.
• Remove old liquid gasket from the bolt holes and threads.

CAUTION:

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

Install O-ring to the cylinder block.

: Engine front

JPBIA4747ZZ

: Engine front

JPBIA4748ZZ

OIL PAN (UPPER)

EM-225

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

Apply a continuous bead of liquid gasket (C) with the tube
presser (commercial service tool) to areas as shown in the fig-
ure.
Use Genuine Liquid Gasket or equivalent.

CAUTION:

Attaching should be done within 5 minutes after coating.

Tighten bolts in the numerical order as shown in the figure.

CAUTION:

Install avoiding misalignment of both oil pan gasket and O-
ring.
• The bolts are different according to the installation position.

Refer to the numbers as shown in the figure.

Install rear oil seal with the following procedure:

CAUTION:

• The installation of rear oil seal should be completed within 5 minutes after installing oil pan

(upper).

• Never touch oil seal lip.

Wipe off any liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using a spatula.

Apply the liquid gasket lightly to entire outside area of new rear oil seal.
Use Genuine Liquid Gasket or equivalent.

: 2 mm (0.07 in) protruded to outside

: 2 mm (0.07 in) protruded to rear oil seal mounting side

: 5.5 - 7.5 mm (0.217 - 0.295 in)

4.0 - 5.0 mm (0.157 - 0.197 in)

: Engine front side

: Engine out side

: Excess of 2 mm or more outward

: Excess of 2 mm or more in the rear oil seal mounting di-
rection

JPBIA4201ZZ

: Engine front

180 mm (7.09 in)

: No. 9, 10

25 mm (0.98 in)

: No. 3, 4, 7, 8

90 mm (3.54 in)

: No. 1, 2, 5, 6

JPBIA4747ZZ

EM-226

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

OIL PAN (UPPER)

Press-fit the rear oil seal using a drift with outer diameter 113
mm (4.45 in) and inner diameter 90 mm (3.54 in) (commercial
service tool) (A).

• Press-fit to the dimensions specified as shown in the figure.

CAUTION:

• Never touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting part

of oil pan (upper) and cylinder block or the crankshaft.

• Press-fit straight check that oil seal does not curl or tilt.

After press-fitting the rear oil seal, completely wipe off any liquid
gasket protruding to rear end surface side.

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

Inspection

INFOID:0000000006449934

INSPECTION AFTER INSTALLATION

Check engine oil level and adjust engine oil. Refer to

LU-25, "Inspection"

Check for leakage of engine oil when engine is warmed.

Stop engine and wait for 10 minutes.

Check engine oil level again. Refer to

LU-25, "Inspection"

PBIC3660E

: Rear oil seal

: Rear end surface of cylinder block

: 0 - 0.5 mm (0 - 0.020 in)

PBIC3149J

CYLINDER BLOCK

EM-227

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

CYLINDER BLOCK

Exploded View

INFOID:0000000006449935

Crankshaft position sensor (POS) cover 2.

Crankshaft position sensor (POS)

O-ring

Drain plug

Cylinder block

Oil level gauge

Oil level gauge guide

O-ring

Knock sensor

JPBIA4749GB

EM-228

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

CYLINDER BLOCK

Disassembly and Assembly

INFOID:0000000006449936

DISASSEMBLY

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

Remove cylinder head. Refer to

EM-208, "Exploded View"

Remove knock sensor.

CAUTION:

Carefully handle knock sensor avoiding shocks.

Remove cover, and then crankshaft position sensor (POS).

CAUTION:

• Avoid impacts such as a dropping.
• Never disassemble.
• Keep it away from metal particles.
• Never place the sensor in a location where it is exposed to

magnetism.

Remove oil pan (upper and lower). Refer to

EM-222, "Exploded View"

Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to

EM-236, "Inspection"

Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.

Remove connecting rod cap.

10. Oil temperature sensor

11.

Oil pressure sensor

12.

Oil jet

13. Top ring

14.

Second ring

15.

Oil ring

16. Piston

17.

Piston pin

18.

Connecting rod

19. Connecting rod bearing (upper)

20.

Main bearing (upper)

21.

Thrust bearing

22. Crankshaft key

23.

Connecting rod bolt

24.

Connecting rod cap

25. Connecting rod bearing (lower)

26.

Main bearing (lower)

27.

Crankshaft

28. Pilot converter (CVT models)

29.

Signal plate

30.

Rear oil seal

31. Drive plate

32.

Rein force plate

33.

Fly wheel (M/T models)

34. Main bearing cap bolt

Tightening must be done following the assembly procedure.
Refer to

EM-228

Chamfered

: Crankshaft side

: Always replace after every disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

: Sealing point

: Should be lubricated with oil.

: Select with proper thickness.

O ring

Crank shaft position sensor (POS)

Cover

: Engine front

JPBIA4202ZZ

CYLINDER BLOCK

EM-229

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.

CAUTION:

• Be careful not to damage matching surface with connect-

ing rod cap.

• Be careful not to damage the cylinder wall and crankshaft

pin, resulting from an interference of the connecting rod
big end.

Remove connecting rod bearings.

CAUTION:

Identify installation positions, and store them without mixing them up.

Remove piston rings form piston.
• Before removing piston rings, check the piston ring side clearance. Refer to

EM-236, "Inspection"

• Use a piston ring expander (commercial service tool) (A).

CAUTION:

• When removing piston rings, be careful not to damage

the piston.

• Be careful not to damage piston rings by expanding

them excessively.

Remove piston from connecting rod.
• Use a piston pin press stand (SST) and a press to remove the

piston pin.

• For the details of SST, refer to the following.

CAUTION:

Be careful not to damage the piston and connecting rod.
NOTE:
The joint between the connecting rod and the piston pin is a
press fit.

Remove the main bearing cap in the following procedure.
• Measure crankshaft end play before loosening main bearing cap bolts. Refer to

EM-236, "Inspection"

Loosen and remove bolts in several steps in reverse of the
numerical order as shown in the figure.

• TORX socket (size: E14) can be used.

Remove the main bearing cap from the cylinder block while tapping lightly with a plastic hammer.

KBIA3365J

PBIC3233J

A : Drift [KV10109730]

B : Center cap [KV10110310]

C : Press stand [ST13030020]

PBIC5270J

: Engine front

JPBIA4203ZZ

EM-230

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

CYLINDER BLOCK

10. Remove crankshaft (2).

CAUTION:

• Be careful not damage or deform signal plate (1) mounted

on crankshaft.

• When setting crankshaft on a flat floor surface, use a

block of wood to avoid interference between signal plate
and the floor surface.

• Never remove signal plate unless it is necessary to do so.
NOTE:
When removing or installing signal plate, use TORX socket (size
T40).

11. Pull rear oil seal out from rear end of crankshaft.
12. Remove main bearing (upper and lower) and thrust bearings from cylinder block and main bearing cap.

CAUTION:

Identify installation positions, and store them without mixing them up.

13. Remove oil jets.

CAUTION:

Insert the dowel pin of oil jet into the cylinder block dowel pin hole to loosen the mounting bolt.

ASSEMBLY

Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.

CAUTION:

Use a goggles to protect your eye.

Install oil jets.

Install main bearings and thrust bearings with the following procedure:

Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block.

Install thrust bearings to the both sides of the No. 3 journal hous-
ing (B) on cylinder block.

• Install thrust bearings with the oil groove (A) facing crankshaft

arm (outside).

Install the main bearings (1) paying attention to the direction.
• Install the one with oil holes (A) onto cylinder block and the

one without oil holes onto main bearing cap.

• Before installing main bearings, apply new engine oil to the

bearing surface (inside). Do not apply engine oil to the back
surface, but thoroughly clean it.

• Ensure the oil holes on cylinder block and those on the corre-

sponding bearing are aligned.

JPBIA4531ZZ

: Engine front

PBIC3258J

PBIC3746E

CYLINDER BLOCK

EM-231

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

• Install the main bearing in the position as shown in the figure.

NOTE:
Install the main bearing in the center position with the following
dimension. For service operation, the center position can be
checked visually.

CAUTION:

Dimension L1 of journal No. 3 is the distance from the housing base end surface (bulk) (it is not
the distance from the thrust bearing mounting end surface).

Install signal plate to crankshaft if removed.

Set the signal plate (1) with the flange facing toward the counter-
weight side (engine front side) to the crankshaft rear surface.

After positioning crankshaft and signal plate with positioning
dowel pin, tighten bolt.
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.

Remove dowel pin.

CAUTION:

Be sure to remove dowel pin.

Install crankshaft to cylinder block.
• While turning crankshaft by hand, check that it turns smoothly.

CAUTION:

Never install rear oil seal yet.

Install main bearing caps.
• Install the main bearing cap while referring to the front mark

(B) and the journal number stamp (A).

NOTE:
Main bearing cap cannot be replaced as a single parts,
because it is machined together with cylinder block.

: Cylinder block

: Main bearing (upper)

: Main bearing (lower)

: Main bearing cap

: Engine front

PBIC3747E

Journal position

No. 1

No. 2

No. 3

No. 4

No. 5

L1 [Unit: mm (in)]

1.65 - 2.05

1.25 - 1.65

2.30 - 2.70

1.25 - 1.65

1.60 - 2.00

(0.064 - 0.080)

(0.049 - 0.064)

(0.090 - 0.106)

(0.049 - 0.064)

(0.062 - 0.078)

L2 [Unit: mm (in)]

1.30 - 1.70

2.30 -2.70

1.30 - 1.70

(0.051 - 0.066)

(0.090 - 0.106)

(0.051 - 0.066)

: Dowel pin hole

: Engine front

JPBIA4231ZZ

JPBIA4204ZZ

EM-232

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

CYLINDER BLOCK

Tighten main bearing cap bolts in numerical order as shown in
the figure with the following steps.

Apply new engine oil to threads and seat surfaces of the mounting bolts.

Tighten main bearing cap bolts.

Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in numerical order as shown in the
figure.

CAUTION:

Check and confirm the tightening angle by using the angle
wrench [SST: KV10112100] (A) or protractor. Avoid judg-
ment by visual inspection without the tool.

• After installing the mounting bolts, check that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to

EM-236, "Inspection"

Install piston to connecting rod with the following procedure:

Set so that the front mark (A) on the piston head and the cylin-
der number (C) are in the position as shown in the figure.

NOTE:
The symbols without notes are for management

: Engine front

JPBIA4203ZZ

: 32.4 N·m (3.3 kg-m, 24 ft-lb)

PBIC3750E

: Oil hole

: Connecting rod big end grade

PBIC3766E

CYLINDER BLOCK

EM-233

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

Press-fit the piston pin using the piston pin press stand (SST).
• For the details of SST, refer to the following.

CAUTION:

Press-fit the piston so as not to damage it.
NOTE:
The joint between the connecting rod and the piston pin is a
press fit.

• Press-fit the piston pin (2) from piston surface (A) to the depth

of 2.35 mm (0.092 in) (b).

• After finishing work, check that the piston (3) moves freely.

Using a piston ring expander (commercial service tool), install piston rings.

CAUTION:

• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
• Position each ring with the gap as shown in the figure referring

to the piston front mark (B).

• Install second ring with the stamped mark (E) facing upward.

10. Install connecting rod bearings to connecting rod and connecting rod cap.

• When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not

apply engine oil to the back surface, but thoroughly clean it.

• Install the bearing in the center position.

NOTE:
There is no stopper tab.

: Drift [KV10109730]

: Center cap [KV10110310]

: Press stand [ST13030020]

: Center shaft KV10114120]

: Spring [ST13030030]

: Detail

PBIC5271J

: Connecting rod

: Press-fit direction

JPBIA2058ZZ

: Oil ring upper or lower rail gap (either of them)

: Second ring and oil ring spacer gap

: Top ring gap

Stamped mark:

Top ring

: 1R

Second ring

: 2R

PBIC3752E

EM-234

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

CYLINDER BLOCK

• Check that the oil holes on connecting rod and connecting rod bearing are aligned.
• Install the connecting rod in the dimension as shown in the fig-

ure.

NOTE:
Install the connecting rod bearing in the center position with
the dimension as shown in the figure. For service operation, the center position can be checked visually.

11. Install piston and connecting rod assembly to crankshaft.

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number on connecting rod to install.
• Using the piston ring compressor [SST: EM03470000] (A) or

suitable tool, install piston with the front mark on the piston
head facing the front of the engine.

CAUTION:

• Be careful not to damage matching surface with con-

necting rod cap.

• Be careful not to damage the cylinder wall and crank-

shaft pin, resulting from an interference of the connect-
ing rod big end.

12. Install connecting rod cap.

• Match the stamped cylinder number marks (C) on connecting

rod with those on connecting rod cap to install.

13. Inspect outer diameter of connecting rod bolts. Refer to

EM-236, "Inspection"

14. Tighten connecting rod bolt with the following procedure:

Apply new engine oil to the threads and seats of connecting rod bolts.

Tighten bolts in several steps.

Completely loosen bolts.

Tighten bolts in several steps.

: Connecting rod

: Connecting rod bearing (upper)

: Connecting rod bearing (lower)

: Connecting rod cap

: 1.7 - 2.1 mm (0.067 - 0.083 in)

: Engine front

PBIC4169E

PBIC3765E

: Front mark

: Oil hole

: Connecting rod big end grade

PBIC3766E

: 27.4 N·m (2.8 kg-m, 20 ft-lb)

: 0 N·m (0 kg-m, 0 ft-lb)

: 19.6 N·m (2.0 kg-m, 14 ft-lb)

CYLINDER BLOCK

EM-235

< UNIT DISASSEMBLY AND ASSEMBLY >

[HR16DE]

Then turn all bolts 60 degrees clockwise (angle tightening).

CAUTION:

Check and confirm the tightening angle by using the angle
wrench [SST: KV10112100] (A) or protractor. Avoid judge-
ment by visual inspection without the tool.

• After tightening connecting rod bolt, check that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to

EM-236, "Inspection"

15. Install oil pan (upper). Refer to

EM-222, "Exploded View"

NOTE:
Install the rear oil seal after installing the oil pan (upper).

16. Install rear oil seal. Refer to

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

17. Install flywheel and drive plate.

M/T models

• Secure flywheel (1) with a stopper plate [SST: KV11105210]

(A), and remove mounting bolts.

• Using TORX socket (size E20), loosen mounting bolts.

CVT models

• Secure drive plate (1) with a stopper plate [SST: KV11105210]

(A), and remove mounting bolts.

• Using TORX socket (size E20), loosen mounting bolts.

CAUTION:

Be careful not to damage or scratch and contact surface for clutch disc of flywheel.

PBIC3753E

MBIB1382E

PBIC3226J

Juke F15 (2012 year). Service Repair Manual - part 192