Nissan Juke (2014 year). Service Repair Manual - part 116

EM-36

< REMOVAL AND INSTALLATION >

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CATALYST

• Prevent rust preventives from adhering to the sensor body.

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TURBOCHARGER

EM-37

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TURBOCHARGER

Exploded View

INFOID:0000000009753576

Removal and Installation

INFOID:0000000009753577

REMOVAL

1.

Heat insulator

2.

Actuator hose

3.

Clamp

4.

Turbocharger inlet tube

5.

Gasket

6.

Gasket

7.

Clamp

8.

Oil outlet hose

9.

Oil return pipe

10. Oil supply tube

11.

O-ring

12. Gasket

13. Turbocharger

14. Eye bolt

15. Gasket

16. Oil supply tube

A.

To boost control solenoid valve

B.

To air inlet hose

C.

To PCV hose

D.

To air duct

E.

To air inlet tube assembly

F.

To catalyst converter

 : N·m (kg-m, ft-lb)

 : N·m (kg-m, in-lb)

 : Always replace after every disassembly.

JSBIA1974GB

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EM-38

< REMOVAL AND INSTALLATION >

[MR16DDT ]

TURBOCHARGER

1.

Drain engine coolant. Refer to 

CO-8, "Draining"

.

2.

Remove engine cover. Refer to 

EM-24, "Exploded View"

.

3.

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

EM-25, "Exploded View"

.

4.

Remove air inlet tube 3. Refer to 

EM-30, "Exploded View"

.

5.

Remove cowl top extension. Refer to 

EXT-25, "Exploded View"

.

6.

Disconnect heated oxygen sensor 2 harness connector. 

7.

Remove front tube. Refer to 

EX-5, "Exploded View"

.

8.

Remove catalyst converter. Refer to 

EM-32, "2WD : Exploded View"

 (2WD models) or 

EM-34, "AWD :

Exploded View"

 (AWD models).

9.

Remove turbocharger assembly as follows:

a.

Remove heat insulator.

b.

Disconnect water hose from turbocharger. Refer to 

EM-27, "Exploded View"

.

c.

Remove oil supply tube.

d.

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:0000000009753578

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.] 

2.

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-

er

Poor ac-

celeration

Turbine wheel

Wet with oil.

C

A

C

C

Carbon deposits observed.

C

A

B

B

“Rubs against” housing.

C

B

A

B

Vane is bent or broken.

A

A

Compressor wheel

Inside of intake port is badly stained 
with oil.

B

B

“Rubs against” housing.

C

B

A

B

Vane is bent or broken.

A

A

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TURBOCHARGER

EM-39

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INSPECTION AFTER REMOVAL

Turbocharger

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.

C

C

B

Cannot be turned by hand.

A

Excessively loose bearing.

C

C

B

C

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

Carbon or sludge deposits in oil drain 
port.

C

A

C

C

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.

A

A: 

Highly possible.

B: 

Possible.

C: 

May exist.

Inspection Location

Result

Symptoms likely to occur when the results shown on 

the left exist.

Oil leakage

Smoke

Noise

Poor pow-

er

Poor ac-

celeration

JPBIA4359ZZ

A.

Check for leakage

Suction side

: Between turbocharger and charge air cooler

Exhaust side

: Between turbocharger and outlet duct

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EM-40

< REMOVAL AND INSTALLATION >

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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-137, "Turbocharger"

.

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EXHAUST MANIFOLD

EM-41

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EXHAUST MANIFOLD

Exploded View

INFOID:0000000009753579

Removal and Installation

INFOID:0000000009753580

REMOVAL

1.

Drain engine coolant. Refer to 

CO-8, "Draining"

.

2.

Remove front tube. Refer to 

EX-5, "Exploded View"

.

3.

Remove turbocharger. Refer to 

EM-37, "Exploded View"

.

4.

Remove exhaust manifold cover.

5.

Remove exhaust manifold. 

JSBIA1975GB

1.

Stud bolt

2.

Exhaust manifold cover

3.

Exhaust manifold

4.

Gasket

Engine front

 : N·m (kg-m, ft-lb)

 : N·m (kg-m, in-lb)

 : Always replace after every disassembly.

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EM-42

< REMOVAL AND INSTALLATION >

[MR16DDT ]

EXHAUST MANIFOLD

• Loosen nuts in reverse order as shown in the figure.

NOTE:
Disregard the numerical order No. 9 to 12 in removal.

6.

Remove gasket.

CAUTION:

Cover engine openings to avoid entry of foreign materials.

INSTALLATION

1.

Install gasket to cylinder head as shown in the figure.

2.

Install exhaust manifold with the following procedure: 

a.

Tighten nuts in numerical order as shown in the figure.

NOTE:
• Tighten nuts the No.1 to No.4 in two steps.
• The numerical order No.9 to No.12 shows the second step.

3.

Install remaining parts in the reverse order of removal.

Inspection

INFOID:0000000009753581

INSPECTION AFTER REMOVAL

Surface Distortion

• Using feeler gauge (A) and straightedge (B), check the surface dis-

tortion of exhaust manifold mating surface in each exhaust port
and entire part.

• If it exceeds the limit, replace exhaust manifold.

: Engine front

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: Engine front

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: Engine front

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Limit

: Refer to 

EM-137, "Exhaust Manifold"

.

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OIL PAN (LOWER)

EM-43

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OIL PAN (LOWER)

Exploded View

INFOID:0000000009753582

1.

O-ring

2.

Oil pan (upper)

3.

Oil level gauge guide

4.

O-ring

5.

Oil level gauge

6.

Oil pump drive chain

7.

Crankshaft sprocket

8.

Oil pump sprocket

9.

Oil pump chain tensioner

10. Oil pump

11.

Drain plug

12. Drain plug washer

13. Oil pan (lower)

14. Oil filter

15. Connector bolt

16. Clamp 

17. Water hose

18. Oil cooler

19. Crankshaft position sensor

20. Gasket

21. Oil pan bolt

22. Rear oil seal

A.

Comply with the assembly proce-
dure when tightening. Refer to 

LU-11

B.

To thermostat hosing

C.

To thermostat housing (M/T models)
To CVT oil warmer (CVT models)

D.

Oil pan side

 : N·m (kg-m, ft-lb)

 : N·m (kg-m, in-lb)

 : Always replace after every disassembly.

 : Sealing point

JPBIA4875GB

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EM-44

< REMOVAL AND INSTALLATION >

[MR16DDT ]

OIL PAN (LOWER)

Removal and Installation

INFOID:0000000009753583

REMOVAL

1.

Drain engine oil. Refer to 

LU-9, "Draining"

.

2.

Remove oil pan (lower) with the following procedure:

a.

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

NOTE:
Disregard the numerical order No.7 and No.11 in removal.

b.

Insert seal cutter [SST: KV10111100 (J-37228)] (A) between oil
pan (upper) and oil pan (lower).

CAUTION:

• Never damage the mating surface.
• Never insert a screwdriver. This damages the mating sur-

faces.

c.

Slide the seal cutter [SST: KV10111100 (J-37228)] by tapping on
the side of tool with a hammer.

d.

Remove oil pan (lower).

INSTALLATION

CAUTION:

Do not reuse drain plug washer.

1.

Install oil pan (lower) as follows:

a.

Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Also remove old liquid gasket from mating surface of oil pan

(upper).

• Remove old liquid gasket from the bolt holes and threads.

CAUTION:

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

 : Should be lubricated with oil.

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

: Engine front

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OIL PAN (LOWER)

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b.

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

Use Genuine RTV Silicon Sealant or equivalent. Refer to 

GI-

24, "Recommended Chemical Products and Sealants"

. 

CAUTION:

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

c.

Tighten bolts in numerical order as shown in the figure. 

NOTE:
• Tighten bolts the No.1 and No.2 in two steps.
• The numerical order No.7 and No.11 shows the second steps.

2.

Install oil pan drain plug.

CAUTION:

Do not reuse drain plug washer.
• Refer to the figure of components of former page for installation direction of drain plug washer. Refer to

EM-107, "Exploded View"

.

3.

Install in the reverse order of removal after this step.

Inspection

INFOID:0000000009753584

INSPECTION AFTER REMOVAL

Clean oil strainer if any object attached.

INSPECTION AFTER INSTALLATION

1.

Check the engine oil level and adjust engine oil. Refer to 

LU-8, "Inspection"

.

2.

Start engine, and check there is no leakage of engine oil.

3.

Stop engine and wait for 10 minutes.

4.

Check the engine oil level again. Refer to 

LU-8, "Inspection"

.

1

: Oil pan (lower)

b

: 7.5 - 9.5 mm (0.295 - 0.374 in)

c

: 

φ

 4.0 - 5.0 mm (0.157 - 0.197 in) 

: Engine outside

: Engine front

JPBIA4367ZZ

: Engine front

JPBIA4364GB

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EM-46

< REMOVAL AND INSTALLATION >

[MR16DDT ]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

Exploded View

INFOID:0000000009753585

CAUTION:

Never remove or disassemble parts unless instructed as shown in the figure.

Removal and Installation

INFOID:0000000009753586

REMOVAL

WARNING:

• Be sure to read 

EM-6, "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

2 

fire extinguisher.

1.

High pressure fuel pump insulator

2.

High pressure fuel pump

3.

O-ring

4.

High pressure fuel pump lifter

5.

Fuel rail connector

6.

Fuel tube

7.

Bracket

8.

Fuel pump connector protector

9.

Fuel feed hose

A.

To centralized under-floor piping

: Engine front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

: Should be lubricated with oil.

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

JSBIA1672GB

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HIGH PRESSURE FUEL PUMP AND FUEL HOSE

EM-47

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• 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-149, "Work Procedure"

.

2.

Remove engine cover. Refer to 

EM-24, "Exploded View"

.

3.

Remove fuel pump connector protector, and remove high pressure fuel pump insulator.

4.

Disconnect quick connector (A) with the following procedure.

a.

Disconnect fuel feed hose (1) from bracket hose clamp (2).

b.

Disengage (A) and pull up (B) the pawl of the fuel feed hose
connector retainer (C) to disconnect the fuel feed hose from high
pressure fuel pump.
NOTE:
If the fuel feed hose is stuck, hold the fuel pipe by hand and dis-
connect it by pushing and pulling.

CAUTION:

• Keep parts away from heat source. Especially, be careful

when welding is performed around them.

• Never expose parts to battery electrolyte or other acids.
• Never bent or twist connection between quick connector

and fuel feed hose (with damper) during installation/
removal.

• Pull quick connector holding (D).
• Never remove the retainer.
• Prepare a tray and waste beforehand as fuel leaks out.
• Never pull with lateral force applied. O-ring inside quick

connector 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.

5.

Remove intake manifold. Refer to 

EM-28, "Removal and Installation"

.

6.

Remove fuel tube.

7.

Remove fuel rail connector.

JPBIA4376ZZ

Retainer color

: Red

JPBIA4377ZZ

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EM-48

< REMOVAL AND INSTALLATION >

[MR16DDT ]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

8.

Remove high pressure fuel pump (1) and lifter.

CAUTION:

To prevent damage to high pressure fuel pump and cam-
shaft bracket, loosen bolt (A) alternately by one turn at a
time until the reaction force applied on the high pressure
fuel pump disappears.

INSTALLATION

CAUTION:

• Do not reuse O-rings.
• To prevent damage to parts due to generated abnormal stress and eccentric load, always observe

the installation procedure.

1.

Install high pressure fuel pump according to the following procedure.

a.

Check the orientation of pump cam from the mounting area
(view arrow) of high pressure fuel pump.

b.

Aim pump cam at the BDC area (arrow position).

NOTE:
For BDC area, anywhere within the area indicated by arrow can
be accepted.

c.

Install O-ring to high pressure fuel pump. When handing new O-ring, paying attention to the following cau-
tion items:

CAUTION:

• Do not reuse O-ring.
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• Never damage O-ring with tools and fingernails during the installation. In addition, twisting or

stretching O-ring is not allowed. If O-ring is stretched during the installation to high pressure
fuel pump, never install high pressure fuel pump immediately.

d.

Install high pressure fuel pump lifter.

e.

Apply oil to the fitting area of high pressure fuel pump O-ring and camshaft bracket side to install high
pressure fuel pump.

f.

Install high pressure fuel pump. To prevent damage to high pressure fuel pump and camshaft bracket, the
following instructions must be observed.

JSBIA1673ZZ

JPBIA4379ZZ

1

: Camshaft (EXH)

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HIGH PRESSURE FUEL PUMP AND FUEL HOSE

EM-49

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CAUTION:

• Temporarily tighten bolt (A) by hand. Alternately tighten

bolt by one turn at a time until high pressure fuel pump
reaches camshaft bracket.

• After a pump flange sitting, tighten the bolts to the speci-

fied torque.

2.

Connect fuel feed hose with the following procedure, and them install the fuel feed hose.

a.

Check no foreign substances are deposited in and around matching pipe and quick connector, and no
damage on them.

b.

Quick connector shall be inserted gradually, aligning with the axis of the matching pipe.

c.

Insert the retainer until it clicks and check the retainer is locked.
After insertion, pull the connector and check that the connector
is locked.

CAUTION:

If retainer cannot be installed smoothly, quick connector
may be have not been installed correctly. Check connection
again.

d.

After attaching the quick connector and fix the hose to the clamp.

3.

Install new fuel rail connector (1).

CAUTION:

• Never reuse fuel rail connector.
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign

material.

• Never scratch O-ring with tools or fingernails when

installing fuel rail connector.

• Insert new fuel rail connector straight into fuel rail. Never decenter or twist the fuel rail connec-

tor during insertion.

4.

Install the fuel tube with the following procedure.

CAUTION:

• When removing fuel tube, always replace fuel rail connector together with fuel tube.
• Never reuse fuel tube.
• Never use fuel tube if its terminal tip is damaged.
• Observe the tightening order and the tightening torque.

1

: High pressure fuel pump

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A

: Lock position

B

: Unlock position 

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2

: O-ring

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EM-50

< REMOVAL AND INSTALLATION >

[MR16DDT ]

HIGH PRESSURE FUEL PUMP AND FUEL HOSE

a.

Temporarily tighten flare nut (A) and (B) of fuel tube (3) until
seated.

CAUTION:

When temporarily tightening flare nut, place pipe in the cen-
ter of the nut inner diameter.

b.

Temporarily tighten bolt (4) until the seat of bracket is seated.

c.

Tighten flare nut (A) and (B) in alphabetical order.

CAUTION:

Always fit the tool completely with the nut.

d.

Tighten bolt (4).

5.

Install in the reverse order of removal after this step.

CAUTION:

After checking fuel leakage, maintain ten minutes of idling to bleed the fuel line.

Inspection

INFOID:0000000009753587

INSPECTION AFTER INSTALLATION

Check for Fuel Leakage

1.

Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check that
there is no fuel leakage at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.

2.

Start the engine. With engine speed increased, check again that there is no fuel leakage at connection
points.

CAUTION:

Never touch the engine immediately after it is stopped because the engine is extremely hot.

1

: High pressure fuel pump

2

: Fuel rail connector

JPBIA5808ZZ

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FUEL INJECTOR AND FUEL TUBE

EM-51

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FUEL INJECTOR AND FUEL TUBE

Exploded View

INFOID:0000000009753588

CAUTION:

• Never remove or disassemble parts unless instructed as shown in the figure.
• When fuel rail insulator (separated type) and adaptor cover (separated type) are removed, be sure to

replace them with fuel insulator (united type).

Removal and Installation

INFOID:0000000009753589

WARNING:

1.

Holder

2.

Seal ring (white)

3.

Backup ring

4.

O-ring (blue)

5.

Fuel injector

6.

Stud bolt

7.

Fuel rail

8.

Fuel rail insulator (united type)

9.

Adaptor cover (separated type)

10. Fuel rail insulator (separated type)

11. Fuel rail cover

12. Fuel pressure sensor

13. Gasket

A.

To fuel rail connector and fuel tube. 
Refer to 

EM-46

.

B.

Comply with the assembly procedure 
when tightening. Refer to 

EM-51

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

: Should be lubricated with oil.

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

JPBIA5902GB

Revision: 2013 October

2014 JUKE