Nissan Juke (2012 year). Service Repair Manual - part 109

EM-26

< REMOVAL AND INSTALLATION >

[MR16DDT ]

AIR CLEANER AND AIR DUCT

Remove air cleaner cover assembly.

Remove mass air flow sensor from air cleaner cover, if necessary.

CAUTION:

Handle the mass air flow sensor with following cares.
• Never shock the mass air flow sensor.
• Never disassemble the mass air flow sensor.
• Never touch the sensor of the mass air flow sensor.

Remove air duct inlet (lower) with the following procedure.

Remove fender protector (LH). Refer to

EXT-21, "Exploded View"

Remove air duct inlet (lower).

INSTALLATION

Note the following, and install in the reverse order of removal.
• Align marks. Attach each joint. Screw clamps firmly.
• Fixing clips shall be fixed after inserting air cleaner body assembly protrusion to air cleaner case botch hole.
• Make sure whether air cleaner body has been firmly installed by shaking it.

Inspection

INFOID:0000000007577432

INSPECTION AFTER REMOVAL

Inspect air duct and resonator assembly for crack or tear.
• If anything found, replace air duct and resonator assembly.

Revision: 2011 October

2012 JUKE

INTAKE MANIFOLD

EM-27

< REMOVAL AND INSTALLATION >

[MR16DDT ]

INTAKE MANIFOLD

Exploded View

INFOID:0000000007577433

Clamp

Water hose

PCV hose

Gasket

Intake manifold

Vacuum tube

Vacuum hose (with check valve)

Vacuum hose

Vacuum gallery assembly

10. EVAP hose

11.

EVAP check valve

12. EVAP hose

13.

EVAP canister purge volume control
solenoid valve

14. Bracket

15. Bracket

16. EVAP hose

17. EVAP service port

18. EVAP hose

19. EVAP tube

20. EVAP hose

21. Water hose

22. Electric throttle control actuator

23. Gasket

To turbocharger

To centralized under-floor piping

To recirculation valve hose

To break booster hose

: N·m (kg-m, ft-lb)

JPBIA4874GB

Revision: 2011 October

2012 JUKE

EM-28

< REMOVAL AND INSTALLATION >

[MR16DDT ]

INTAKE MANIFOLD

Removal and Installation

INFOID:0000000007577434

REMOVAL

Remove engine cover. Refer to

EM-24, "Exploded View"

Pull out oil level gauge.

CAUTION:

Cover the oil level gauge guide openings to avoid entry of foreign materials.

Disconnect turbocharger boost sensor (with intake air temperature sensor 2) harness connector. Refer to

EM-30, "Exploded View"

Remove air inlet tube assembly. Refer to

EM-30, "Exploded View"

Disconnect water hoses from electric throttle control actuator as follows:
• Attach plug to prevent engine coolant leakage when engine coolant is not drained. Refer to

CO-8,

"Draining"

CAUTION:

Perform this step when the engine is cold.
NOTE:
This step is not required when removing only intake manifold.

Disconnect electric throttle control actuator harness connector.

Remove electric throttle control actuator.

CAUTION:

• Handle carefully to avoid any shock to electric throttle control actuator.
• Never disassemble electric throttle control actuator.

Remove EVAP vacuum tank.

Disconnect EVAP canister purge volume control solenoid valve harness connector, and them remove
bracket with EVAP canister purge volume control solenoid valve.

10. Remove vacuum gallery.

11. Disconnect PCV hose (intake manifold side).

12. Remove intake manifold (1) with the following procedure.

• Loosen and remove intake manifold mounting bolt (A).

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

NOTE:
Disregard the numerical order No.6 in removal.

CAUTION:

Cover engine openings to avoid entry of foreign materi-
als.

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

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

JPBIA4385ZZ

: Engine front

JPBIA4356ZZ

Revision: 2011 October

2012 JUKE

INTAKE MANIFOLD

EM-29

< REMOVAL AND INSTALLATION >

[MR16DDT ]

INSTALLATION

Note the following, and install in the reverse order of removal.

Intake Manifold

Check if gasket is not dropped from the installation groove of intake manifold.

Install intake manifold with the following procedure:

Tighten in numerical order as shown in the figure.

NOTE:
• Tighten bolt the No.1 in two steps.
• The numerical order No.6 shows the second step.

Install in the reverse order of removal after this step.

CAUTION:

Since check valve is built-in inside vacuum hose (1), install
the vacuum hose fitting the arrow (A) to intake manifold
side (2).

Electric Throttle Control Actuator

• Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
• Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the elec-

tric throttle control actuator. Refer to

EC-131, "Work Procedure"

• Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing

electric throttle control actuator. Refer to

EC-131, "Work Procedure"

and

EC-132, "Work Procedure"

Inspection

INFOID:0000000007577435

INSPECTION AFTER REMOVAL

Vacuum hose (with check valve)

Check that the check valve. Refer to

BR-40, "Inspection"

: Engine front

JPBIA4356ZZ

JPBIA4441ZZ

Revision: 2011 October

2012 JUKE

EM-30

< REMOVAL AND INSTALLATION >

[MR16DDT ]

CHARGE AIR COOLER

CHARGE AIR COOLER

Exploded View

INFOID:0000000007577436

Removal and Installation

INFOID:0000000007577437

REMOVAL

Air inlet hose 1, Air inlet tube 1 and Recirculation valve

Remove engine cover. Refer to

EM-24, "Exploded View"

Air inlet tube 3

Mounting rubber (gray)

Air inlet tube bracket

Clamp

Air inlet hose 2

Gasket

Turbocharger

Mounting rubber

Charge air cooler

10. Air inlet tube 2

11.

Air inlet tube bracket

12. Air inlet hose 1

13. Air inlet tube 1

14. O-ring

15. Turbocharger boost sensor

16. Grommet

17. Mounting rubber (black)

18. Air inlet hose

19. Clamp

20. Recirculation valve

21. Clamp

22. Vacuum hose

To vacuum gallery assembly

To electric throttle control actuator

To turbocharger

: Vehicle front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

: Should be lubricated with oil.

JPBIA5704GB

Revision: 2011 October

2012 JUKE

CHARGE AIR COOLER

EM-31

< REMOVAL AND INSTALLATION >

[MR16DDT ]

Make matching marks on each connecting part for reference at installation.

Remove recirculation hose and vacuum hose to recirculation valve.

Loosen clamp, and then remove air inlet hose 1.

Remove recirculation valve and turbocharger boost sensor from air inlet tube 1, if necessary.

loosen clamp, and then remove air inlet hose 1.

Air inlet tube 3

Remove engine cover. Refer to

EM-24, "Exploded View"

Make matching marks on each connecting part for reference at installation.

Loosen clamp, and then remove air inlet tube 3.

Charge air cooler, Air inlet hose 2 and Air inlet tube 2

Remove front bumper. Refer to

EXT-11, "Exploded View"

Remove radiator core support upper. Refer to

DLK-123, "Exploded View"

(With intelligent key system) or

DLK-238, "Exploded View"

(Without intelligent key system).

Make matching marks on each connecting part for reference at installation.

Remove air inlet hose 2.

Loosen air inlet tube 2 clamp, and then remove charge air cooler
(1).

CAUTION:

• Avoid interference between the charge air cooler and radi-

ator.

• When removing charge air cooler, close opening on turbo

charger and intake manifold with shop cloth or other suit-
able material.

Remove air inlet tube 2, if necessary.

INSTALLATION

Install in the reverse order of removal paying attention to the following points:

CAUTION:

Do not reuse O-rings.
• Apply a neutral detergent (fluid) to the joint between hoses and pipes (oil is not permissible).
• Pay attention to identification mark and direction.

Inspection

INFOID:0000000007577438

INSPECTION AFTER REMOVAL

Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it
dry.

Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler in necessary.
• Be careful not to deform core fins.
• For cleaning procedure of charge air cooler core, refer to

CO-16, "Inspection"

JPBIA4357ZZ

Revision: 2011 October

2012 JUKE

EM-32

< REMOVAL AND INSTALLATION >

[MR16DDT ]

CATALYST

CATALYST

2WD

2WD : Exploded View

INFOID:0000000007577439

2WD : Removal and Installation

INFOID:0000000007577440

REMOVAL

Remove engine cover. Refer to

EM-24, "Exploded View"

Remove cowl top extension. Refer to

EXT-19, "Exploded View"

Remove front tube. Refer to

EX-5, "Exploded View"

Remove catalyst converter support bracket (lower).

Remove A/F sensor 1.
• Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], remove A/F sensor 1.

CAUTION:

• Never damage air fuel ratio sensor 1.
• Discard any sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a

hard surface such as a concrete floor; use a new one.

JPBIA4321GB

A/F sensor 1

Catalyst converter shroud upper

Gasket

Catalyst converter

Catalyst converter support bracket
(lower)

Catalyst converter support bracket
(upper)

To exhaust system

Engine front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

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

Revision: 2011 October

2012 JUKE

CATALYST

EM-33

< REMOVAL AND INSTALLATION >

[MR16DDT ]

Remove catalyst converter shroud upper.

Remove bolts and nut of catalyst converter turbocharger side.

Remove catalyst converter support bracket (upper).

Remove heat insulator. Refer to

FAX-18, "Exploded View"

10. Remove catalyst converter.
11. Remove gasket.

INSTALLATION

Install gasket between turbocharger and catalyst as shown in
the figure.

Install catalyst converter with the following procedure.
• Tighten in numerical order as shown in the figure.
- Install catalyst converter (base on stud position 1).
- Temporary assemble 2 (no priority).
- Temporary assemble 3, 4.
- Tightening 5, 6 and 7.
- Tightening again 8, 9 and 10.
- Temporary assemble 11.
- Tightening 12,13,14,and 15.

Note the following, and install in the reverse order of removal.
A/F sensor 1
• Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], install A/F sensor 1.

CAUTION:

• Before installing a new sensors, clean exhaust system threads using heated oxygen sensor

thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply anti-seize
lubricant.

• Never apply excessive torque to sensor 2. Doing so may cause damage to sensor 2, resulting

in the “MIL” illuminating.

• Prevent rust preventives from adhering to the sensor body.

AWD

: Gasket

: Turbocharger side

: Catalyst converter side

: Claw

JPBIA4418ZZ

JPBIA4362GB

Revision: 2011 October

2012 JUKE

EM-34

< REMOVAL AND INSTALLATION >

[MR16DDT ]

CATALYST

AWD : Exploded View

INFOID:0000000007577441

AWD : Removal and Installation

INFOID:0000000007577442

REMOVAL

Drain engine coolant. Refer to

CO-8, "Draining"

Remove engine cover. Refer to

EM-24, "Exploded View"

Remove cowl top extension. Refer to

EXT-19, "Exploded View"

Remove front tube. Refer to

EX-5, "Exploded View"

Remove catalyst converter support bracket (lower).

Remove A/F sensor 1 and heated oxygen sensor 2.
• Use heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], remove A/F sensor 1 and heated

oxygen sensor 2.

CAUTION:

• Never damage air fuel ratio sensor 1 and heated oxygen sensor 2.
• Discard any sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a

hard surface such as a concrete floor; use a new one.

JPBIA4345GB

A/F sensor 1

Catalyst converter shroud upper

Gasket

Heated oxygen sensor 2

Catalyst converter support bracket
(lower)

Catalyst converter

Catalyst converter support bracket
(upper)

To exhaust system

Engine front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

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

Revision: 2011 October

2012 JUKE

CATALYST

EM-35

< REMOVAL AND INSTALLATION >

[MR16DDT ]

Remove catalyst converter shroud (upper).

Remove bolts and nut of catalyst converter turbocharger side.

Remove heat insulator. Refer to

DLN-95, "Exploded View"

10. Remove catalyst converter support bracket (upper).

11. Remove catalyst converter. And keep a service area.

NOTE:
Slide the catalyst converter in a lateral direction to obtain work space for removing turbocharger.

12. Remove turbocharger. Refer to

EM-37, "Exploded View"

13. Pull up and remove catalyst converter.
14. Remove gasket.

INSTALLATION

Install gasket between turbocharger and catalyst as shown in
the figure.

Note the following, and install in the reverse order of removal.
A/F sensor 1 and Heated oxygen sensor 2
• Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], install A/F sensor 1 and heated

oxygen sensor 2.

CAUTION:

• Before installing a new sensors, clean exhaust system threads using heated oxygen sensor

thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply anti-seize
lubricant.

• Never apply excessive torque to sensors. Doing so may cause damage to sensors, resulting in

the “MIL” illuminating.

: Gasket

: Turbocharger side

: Catalyst converter side

: Claw

JPBIA4418ZZ

JPBIA4371GB

Revision: 2011 October

2012 JUKE

EM-36

< REMOVAL AND INSTALLATION >

[MR16DDT ]

CATALYST

• Prevent rust preventives from adhering to the sensor body.

Revision: 2011 October

2012 JUKE

TURBOCHARGER

EM-37

< REMOVAL AND INSTALLATION >

[MR16DDT ]

TURBOCHARGER

Exploded View

INFOID:0000000007577443

Removal and Installation

INFOID:0000000007577444

REMOVAL

Heat insulator

Actuator hose

Clamp

Turbocharger inlet tube

Gasket

Clamp

Oil outlet hose

Oil return pipe

10. Oil supply tube

11.

O-ring

12. Gasket

13. Turbocharger

14. Eye bolt

15. Gasket

16. Oil supply tube

To boost control solenoid valve

To air inlet hose

To PCV hose

To air duct

To air inlet tube assembly

To catalyst converter

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JSBIA1974GB

Revision: 2011 October

2012 JUKE

EM-38

< REMOVAL AND INSTALLATION >

[MR16DDT ]

TURBOCHARGER

Drain engine coolant. Refer to

CO-8, "Draining"

Remove engine cover. Refer to

EM-24, "Exploded View"

Remove air cleaner cover assembly and air cleaner body assembly. Refer to

EM-25, "Exploded View"

Remove air inlet tube 3. Refer to

EM-30, "Exploded View"

Remove cowl top extension. Refer to

EXT-19, "Exploded View"

Disconnect heated oxygen sensor 2 harness connector.

Remove front tube. Refer to

EX-5, "Exploded View"

Remove catalyst converter. Refer to

EM-32, "2WD : Exploded View"

(2WD models) or

EM-34, "AWD :

Exploded View"

(AWD models).

Remove turbocharger assembly as follows:

Remove heat insulator.

Disconnect water hose from turbocharger. Refer to

EM-27, "Exploded View"

Remove oil supply tube.

Remove mounting nuts of turbocharger.

CAUTION:

Never deform each turbocharger piping when pulling out the assembly.

INSTALLATION

CAUTION:

Do not reuse O-rings.
Install in the reverse order of removal.

Inspection

INFOID:0000000007577445

INSPECTION PROCERDURE

Trouble Diagnosis of Turbocharger
Check items before trouble diagnosis
1.

Check that the engine oil level is between L (Low level) and H (High level) of the oil level gauge. [When
the engine oil amount is more then H (High level), the engine oil flows into the inlet duct through the blow-
by gas passage, and the turbocharger is misjudged failure.]

Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.
• Replace the exhaust manifold and turbocharger assembly when any malfunction is found after unit

inspections specified in the table below.

• If no malfunction is found after the unit inspections, judge that the turbocharger body has no non-stan-

dard conditions. Check the other parts again.

Inspection Location

Result

Symptoms likely to occur when the results shown on

the left exist.

Oil leakage

Smoke

Noise

Poor pow-

Poor ac-

celeration

Turbine wheel

Wet with oil.

Carbon deposits observed.

“Rubs against” housing.

Vane is bent or broken.

Compressor wheel

Inside of intake port is badly stained
with oil.

“Rubs against” housing.

Vane is bent or broken.

Revision: 2011 October

2012 JUKE

TURBOCHARGER

EM-39

< REMOVAL AND INSTALLATION >

[MR16DDT ]

INSPECTION AFTER REMOVAL

Turbocharger

CAUTION:

When the compressor wheel, turbine wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary failure:

Turbocharger Boost Control

Check both turbine and compres-
sor rotor shaft end play.

Heavy feel or catching when turned by
hand.

Cannot be turned by hand.

Excessively loose bearing.

Rotor shaft, oil return port (Check
inside using penlight.)

Carbon or sludge deposits in oil drain
port.

Boost control valve actuator oper-
ation (using a handy pump)

• Does not operate smoothly when air

pressure is gradually applied.

• Stroke amount is not compliance

with the air pressure.

Highly possible.

Possible.

May exist.

Inspection Location

Result

Symptoms likely to occur when the results shown on

the left exist.

Oil leakage

Smoke

Noise

Poor pow-

Poor ac-

celeration

JPBIA4359ZZ

Check for leakage

Suction side

: Between turbocharger and charge air cooler

Exhaust side

: Between turbocharger and outlet duct

Revision: 2011 October

2012 JUKE

EM-40

< REMOVAL AND INSTALLATION >

[MR16DDT ]

TURBOCHARGER

• Connect the a pressurized handy pump (A) to the actuator, and

check that the rod strokes smoothly in compliance with the follow-
ing pressure.

INSPECTION AFTER INSTALLATION

Start engine and raise engine speed to check no exhaust emission leaks.

Standard (value of pressure/Value of rod moving):

Refer to

EM-136, "Turbocharger"

JPBIA0665ZZ

Revision: 2011 October

2012 JUKE

EXHAUST MANIFOLD

EM-41

< REMOVAL AND INSTALLATION >

[MR16DDT ]

EXHAUST MANIFOLD

Exploded View

INFOID:0000000007577446

Removal and Installation

INFOID:0000000007577447

REMOVAL

Drain engine coolant. Refer to

CO-8, "Draining"

Remove front tube. Refer to

EX-5, "Exploded View"

Remove turbocharger. Refer to

EM-37, "Exploded View"

Remove exhaust manifold cover.

Remove exhaust manifold.

JSBIA1975GB

Stud bolt

Exhaust manifold cover

Exhaust manifold

Gasket

Engine front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

Revision: 2011 October

2012 JUKE

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