Index Manuals Nissan Juke (2016 year) - Service and Repair Manual

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Nissan Juke (2016 year). Service Repair Manual - part 306

EM-4

Exploded View .......................................................

Removal and Installation .......................................

Inspection ..............................................................

IGNITION COIL, SPARK PLUG AND ROCK-
ER COVER .......................................................

Exploded View .......................................................

Removal and Installation .......................................

UNIT REMOVAL AND INSTALLATION ....

ENGINE ASSEMBLY .......................................

2WD ..........................................................................

2WD : Exploded View ............................................

2WD : Removal and Installation ............................

2WD : Inspection ...................................................

AWD .........................................................................

AWD : Exploded View ...........................................

AWD : Removal and Installation ............................

AWD : Inspection ...................................................

UNIT DISASSEMBLY AND ASSEMBLY ...

ENGINE STAND SETTING ..............................

Installation .............................................................

ENGINE UNIT ..................................................

Disassembly and Assembly ...................................

FLYWHEEL ......................................................

Exploded View .......................................................

Removal and Installation .......................................

Inspection ..............................................................

DRIVE PLATE ..................................................

Exploded View .......................................................

Removal and Installation .......................................

Inspection ..............................................................

DRIVE BELT AUTO TENSIONER AND IDLER
PULLEY ...........................................................

Exploded View .......................................................

Removal and Installation .......................................

CATALYST ......................................................

2WD ..........................................................................

2WD : Exploded View ............................................

2WD : Removal and Installation ............................

AWD .........................................................................

AWD : Exploded View ...........................................

AWD : Removal and Installation ............................

EGR SYSTEM ..................................................

Exploded View .......................................................

Removal and Installation .......................................

Disassembly and Assembly ...................................

Inspection ..............................................................

EXHAUST MANIFOLD AND TURBOCHARG-
ER ASSEMBLY ................................................

Exploded View ......................................................

Removal and Installation .......................................

Inspection ..............................................................

TIMING CHAIN .................................................

Exploded View ......................................................

Removal and Installation .......................................

Inspection ..............................................................

CAMSHAFT ......................................................

Exploded View ......................................................

Removal and Installation .......................................

Inspection ..............................................................

OIL SEAL ..........................................................

VALVE OIL SEAL ...................................................

VALVE OIL SEAL : Removal and Installation .......

FRONT OIL SEAL ...................................................

FRONT OIL SEAL : Removal and Installation ......

REAR OIL SEAL .....................................................

REAR OIL SEAL : Removal and Installation .........

CYLINDER HEAD .............................................

Exploded View ......................................................

Removal and Installation .......................................

Disassembly and Assembly ..................................

Inspection ..............................................................

OIL PAN (UPPER) ............................................

Exploded View ......................................................

Removal and Installation .......................................

Inspection ..............................................................

CYLINDER BLOCK ..........................................

Exploded View ......................................................

Disassembly and Assembly ..................................

Inspection ..............................................................

HOW TO SELECT PISTON AND BEARING ...

Selective-fit Service Parts .....................................

SERVICE DATA AND SPECIFICATIONS
(SDS) .........................................................

SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................

General Specification ............................................

Drive Belt ..............................................................

Air Cleaner ............................................................

Spark Plug ............................................................

Exhaust Manifold ..................................................

Camshaft ...............................................................

Cylinder Head .......................................................

Cylinder Block .......................................................

Connecting Rod Bearing .......................................

Main Bearing .........................................................

Revision: November 2015

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PRECAUTIONS

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PRECAUTION

PRECAUTIONS

Precautions for Removing Battery Terminal

INFOID:0000000012958640

When disconnecting the battery terminal, pay attention to the following.

• Always use a 12V battery as power source.

• Never disconnect battery terminal while engine is running.

• When removing the 12V battery terminal, turn OFF the ignition

switch and wait at least 30 seconds.

• For vehicles with the engine listed below, remove the battery termi-

nal after a lapse of the specified time:

NOTE:

ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal

is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.

• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait

for at least 15 minutes to remove the battery terminal.

NOTE:

• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF.

• Example of high-load driving

- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.

- Driving for 30 minutes or more on a steep slope.

• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON

the ignition switch.

NOTE:

If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon-

nected, then DTC may be detected.

• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.

NOTE:

The removal of 12V battery may cause a DTC detection error.

Precaution for Procedure without Cowl Top Cover

INFOID:0000000012197228

When performing the procedure after removing cowl top cover, cover

the lower end of windshield with urethane, etc to prevent damage to

windshield.

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"

INFOID:0000000012197229

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along

with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain

D4D engine

: 20 minutes

YS23DDT

: 4 minutes

HRA2DDT

: 12 minutes

YS23DDTT

: 4 minutes

K9K engine

: 4 minutes

ZD30DDTi

: 60 seconds

M9R engine

: 4 minutes

ZD30DDTT

: 60 seconds

R9M engine

: 4 minutes

V9X engine

: 4 minutes

YD25DDTi

: 2 minutes

SEF289H

PIIB3706J

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PRECAUTIONS

types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS

system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front

air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.

Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this

Service Manual.

WARNING:

Always observe the following items for preventing accidental activation.

• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in

the event of a collision that would result in air bag inflation, it is recommended that all maintenance

and repair be performed by an authorized NISSAN/INFINITI dealer.

• Improper repair, including incorrect removal and installation of the SRS, can lead to personal injury

caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module,

see “SRS AIR BAG”.

• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-

vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness

connectors.

PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS

WARNING:

Always observe the following items for preventing accidental activation.

• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the

ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with

a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing

serious injury.

• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the

battery or batteries, and wait at least 3 minutes before performing any service.

Special Cautions to Ensure the Safe Disposal of Sodium-filled Exhaust Valves

INFOID:0000000012197230

Handling and disposal of sodium-filled exhaust valves requires spe-

cial care and consideration. Under conditions such as breakage with

subsequent contact with water, metal sodium which lines the inner

portion of exhaust valve will react violently, forming sodium hydrox-

ide and hydrogen which may result in an explosion. Sodium-filled

exhaust valve is identified on the top of its stem as shown in illustra-

tion.

DEALER DISPOSAL INSTRUCTIONS

CAUTION:

• Use approved shatter-resistant eye protection when performing this procedure.

• Perform this and all subsequent disposal work procedures in an open room, away from flammable

liquids. Keep a fire extinguisher, rated at least 10 ABC, in close proximity to the work area.

• Be sure to wear rubber gloves when performing the following operations.

• Make sure the resultant (high alkalinity) waste water does not contact your skin. If the waste water

does contact you, wash the contacted area immediately with large quantities of water.

• Dealers should check their respective state and local regulations concerning any chemical treatment

or waste water discharge permits which may be required to dispose of the resultant (high alkalinity)

waste water.

A

: Identification mark of sodium-filled exhaust valve

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1. Clamp valve stem in a vice.
2. The valve has a specially-hardened surface. To cut through it,

first remove a half-round section, approximately 30 mm (1.18 in)

long using air-powered grinder until black color is removed and

silver color appears.

3. Use hacksaw to cut through approximately half the diameter of

valve stem. Make the serration at a point 40 mm (1.57 in) from

the end of valve stem.

4. Cover the serrated end of the valve with a large shop towel (A).

Strike the valve face end with a hammer, separating it into two

pieces.

5. Fill a bucket (such as a 20 oil can) with at least 10 (2-5/8

US gal, 2-1/4 lmp gal) of water. Carefully place the alreadycut

(serrated) valves into the water one-at-a-time using a set of

large tweezers and quickly move away at least 2.7 m (9 ft).

6. The valves should be placed in a standing position as shown in

the illustration to allow complete reaction. After the bubbling

action has subsided, additional valves can be placed into the

bucket allowing each subsequent chemical reaction to subside.

However, no more than 8 valves should be placed in the same
10 (2-5/8 US gal, 2-1/4 lmp gal) amount of water. The com-

plete chemical reaction may take as long as 4 to 5 hours.

Remove the valves using a set of large tweezers after the chem-

ical reaction has stopped. Afterwards, valves can be disposed

as ordinary scrap.

Precautions For Engine Service

INFOID:0000000012197231

DISCONNECTING FUEL PIPING

• Before starting work, check no fire or spark producing items are in the work area.

• Release fuel pressure before disconnecting and disassembly.

• After disconnecting pipes, plug openings to stop fuel leakage.

DRAINING ENGINE COOLANT

Drain engine coolant and engine oil when the engine is cooled.

A

: Black color

B

: Silver color

c

: 47 mm (1.85 in)

d

: 17 mm (0.67 in)

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a

: 32 mm (1.26 in)

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A

: Bucket (Such as 20 oil can)

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PRECAUTIONS

INSPECTION, REPAIR AND REPLACEMENT

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and

replace if necessary.

REMOVAL AND DISASSEMBLY

• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin-

structed operations.

• Exercise maximum care to avoid damage to mating or sliding surfaces.

• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,

check that dowel pins are installed in the original position.

• Must cover openings of engine system with a tape or equivalent, to seal out foreign materials.

• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.

• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally

opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used

in the step.

ASSEMBLY AND INSTALLATION

• Use torque wrench to tighten bolts or nuts to specification.

• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the

ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,

do exactly as specified.

• Replace with new gasket, packing, oil seal or O-ring.

• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for

any restriction and blockage.

• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.

Before assembly, oil sliding surfaces well.

• After disassembling, or exposing any internal engine parts, change engine oil and replace oil filter with a new

one.

• Release air within route when refilling after draining engine coolant.

• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and

exhaust gases for leakage.

Precaution for Handling High Pressure Fuel System

INFOID:0000000012197232

• High pressure fuel system components are between high pressure fuel pump and fuel injector.

• Always release fuel pressure and never start the engine when performing removal and installation.

• When removing or installing parts without releasing fuel pressure, fuel may be splashed and, if fuel contacts

skin or eyes, it may cause inflammation.

Parts Requiring Angle Tightening

INFOID:0000000012197233

• Use the angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts:

- Camshaft sprocket (INT) bolt

- Cylinder head bolts

- Main bearing cap bolts

- Connecting rod cap bolts

- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle

tightening)

• Do not use a torque value for final tightening.

• The torque value for these parts are for a preliminary step.

• Ensure thread and seat surfaces are clean and coated with engine oil.

Liquid Gasket

INFOID:0000000012197234

REMOVAL OF LIQUID GASKET SEALING

Revision: November 2015

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• After removing mounting nuts and bolts, separate the mating sur-

face using the seal cutter [SST: KV10111100 (J-37228)] (A) and

remove old liquid gasket sealing.

CAUTION:

Be careful not to damage the mating surfaces.

• Tap the seal cutter [SST: KV10111100 (J-37228)] to insert it (B),

and then slide it (C) by tapping on the side as shown in the figure.

• In areas where the seal cutter [SST: KV10111100 (J-37228)] is dif-

ficult to use, lightly tap the parts using a plastic hammer to remove

it.

CAUTION:

If for some unavoidable reason tool such as a screwdriver is

used, be careful not to damage the mating surfaces.

LIQUID GASKET APPLICATION PROCEDURE

1. Using a scraper (A), remove old liquid gasket adhering to the liq-

uid gasket application surface and the mating surface.

• Remove liquid gasket completely from the groove of the liquid

gasket application surface, mounting bolts, and bolt holes.

2. Wipe the liquid gasket application surface and the mating sur-

face with white gasoline (lighting and heating use) to remove

adhering moisture, grease and foreign materials.

3. Attach liquid gasket tube to the tube presser (commercial ser-

vice tool).

Use Genuine RTV Silicon Sealant or equivalent. Refer to

22, "Recommended Chemical Products and Sealants"

.

4. Apply liquid gasket without gaps to the specified location accord-

ing to the specified dimensions.

• If there is a groove for liquid gasket application, apply liquid

gasket to the groove.

• As for bolt holes (B), normally apply liquid gasket inside the

holes. Occasionally, it should be applied outside the holes.

Check to read the text of this manual.

• Within five minutes of liquid gasket application, install the mat-

ing component.

• If liquid gasket protrudes, wipe it off immediately.

• Do not retighten mounting bolts or nuts after the installation.

• After 30 minutes or more have passed from the installation, fill

engine oil and engine coolant.

CAUTION:

If there are specific instructions in this manual, observe them.

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EMA0622D

A

: Groove

: Inside

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[MR FOR NISMO RS MODELS]

PREPARATION

PREPARATION

PREPARATION

Special Service Tools

INFOID:0000000012197235

The actual shapes oh TechMate tools may differ from those of special service tools illustrated here.

Tool number
(TechMate No.)
Tool name

Description

KV10111100
(J-37228)
Seal cutter

Removing oil pan (upper and lower) etc.

KV10114400
(J-38365)
Heated oxygen sensor wrench

Loosening or tightening heated oxygen sen-
sor 2 (AWD models)

a: For 22 mm (0.87 in) width hexagon nut

KV10116200
(J-26336-A)
Valve spring compressor
1. KV10115900
(J-26336-20)
Attachment
2. KV10109220
( — )
Adapter

Disassembling and assembling valve mecha-
nism
Part (1) is a component of KV10116200 (J-
26336-A), but Part (2) is not so.

KV10112100
(BT8653-A)
Angle wrench

Tightening bolts for main bearing cap, cylinder
head, etc.

KV10117100
(J-3647-A)
Heated oxygen sensor wrench

Loosening or tightening air fuel ratio sensor 1

For 22 mm (0.87 in) width hexagon nut

KV10107902
(J-38959)
Valve oil seal puller

Removing valve oil seal

S-NT046

S-NT636

PBIC1650E

S-NT014

NT379

NT011

Revision: November 2015

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PREPARATION

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KV10115600
(J-38958)
Valve oil seal drift

Installing valve oil seal

Use side A (G).
a: 20 (0.79) dia.          d: 8 (0.31) dia.
b: 13 (0.51) dia.           e: 10.7 (0.421)
c: 10.3 (0.406) dia.         f: 5 (0.20)
H: Side B

Unit: mm (in)

EM03470000
(J-8037)
Piston ring compressor

Installing piston assembly into cylinder bore

ST16610001
(J-23907)
Pilot bushing puller

Removing pilot converter

KV11103000
( — )
Pulley puller

Removing crankshaft pulley

KV11105210
(J-44716)
Stopper plate

Fixing drive plate

KV10119600
( — )
Injector remover

Removing fuel injector

KV101197S0
( — )
Injector seal drift set

Installing fuel injector seal ring

Tool number
(TechMate No.)
Tool name

Description

JPBIA0396ZZ

S-NT044

S-NT045

NT676

ZZA0009D

JPBIA3746ZZ

JPBIA3281ZZ

Revision: November 2015

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