Engine Mechanical: Diagnosis Nissan Juke I

Inspection, Repair and Replacement

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

INSPECTION

Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if there is unusual engine conditions regarding valve clearance.

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1. Remove rocker cover. Refer to " «EXPLODED VIEW»(ref-516394-S05809942372012120600000) ".
2. Measure the valve clearance with the following procedure: Set No. 1 cylinder at TDC of its compression stroke. Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front cover. At the same time, check that both intake and exhaust cam noses of No. 1 cylinder face inside (<==) as shown in the figure. If they do not face inside, rotate crankshaft pulley once more (360 degrees) and align as shown in the figure. Use a feeler gauge, measure the clearance between valve lifter and camshaft. Valve clearance: Refer to " «CAMSHAFT»(ref-516394-S39024377212012120600000) ". By referring to the figure, measure the valve clearances at locations marked "x" as shown in the table below [locations indicated with black arrow (<==) in the figure] with a feeler gauge. Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL. No. 1 cylinder at compression TDC EXH x x INT x x Set No. 4 cylinder at TDC of its compression stroke. Rotate crankshaft pulley (1) one revolution (360 degrees) and align TDC mark (no paint) (B) to timing indicator (A) on front cover. By referring to the figure, measure the valve clearance at locations marked "x" as shown in the table below [locations indicated with black arrow (<==) in the figure] with a feeler gauge. Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL. No. 4 cylinder at compression TDC EXH x x INT x x
3. If out of standard, perform adjustment. Refer to " «ADJUSTMENT»(ref-516394-S04796273152012120600000) ".

INSPECTION AFTER REMOVAL

Examine with eyes that there is no stain, clogging, or damage on air cleaner element.

1. Remove dusts (such as dead leafs) on air cleaner element surface and inside cleaner case.
2. If clogging or damage is observed, replace the air cleaner element. CAUTION: Never clean the viscous paper type air cleaner element by blowing as there is a risk of deterioration of its performance.

Use the standard type spark plug for normal condition.

Spark plug (Standard type): Refer to " SPARK PLUG ".

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Inspect air duct and resonator assembly for crack or tear.

1. If anything found, replace air duct and resonator assembly.

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1. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ".
2. Pull out oil level gauge. CAUTION: Cover the oil level gauge guide openings to avoid entry of foreign materials.
3. Disconnect turbocharger boost sensor (with intake air temperature sensor 2) harness connector. Refer to " «EXPLODED VIEW»(ref-516394-S42591055892012120600000) ".
4. Remove air inlet tube assembly. Refer to " «EXPLODED VIEW»(ref-516394-S42591055892012120600000) ".
5. 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 " «DRAINING»(ref-516398-S08374559152012120600000) ". CAUTION: Perform this step when the engine is cold. NOTE: This step is not required when removing only intake manifold.
6. Disconnect electric throttle control actuator harness connector.
7. Remove electric throttle control actuator. CAUTION: Handle carefully to avoid any shock to electric throttle control actuator. Never disassemble electric throttle control actuator.
8. Remove EVAP vacuum tank.
9. 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 materials.

1. Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it dry.
2. 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 " «INSPECTION»(ref-516398-S31574068642012120600000) ".

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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-standard 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 power Poor acceleration 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 Check both turbine and compressor 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 operation (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.

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1. Connect the a pressurized handy pump (A) to the actuator, and check that the rod strokes smoothly in compliance with the following pressure. Standard (value of pressure/Value of rod moving): Refer to " «TURBOCHARGER»(ref-516394-S38133042112012120600000) ".

INSPECTION AFTER INSTALLATION

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

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1. Drain engine coolant. Refer to " «DRAINING»(ref-516398-S08374559152012120600000) ".
2. Remove front tube. Refer to " «EXPLODED VIEW»(ref-516401-S42421858012012120600000) ".
3. Remove turbocharger. Refer to " «EXPLODED VIEW»(ref-516394-S42028742692012120600000) ".
4. Remove exhaust manifold cover.
5. Remove 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.

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1. Install gasket to cylinder head as shown in the figure.
2. Install exhaust manifold with the following procedure: 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.

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1. Using feeler gauge (A) and straightedge (B), check the surface distortion of exhaust manifold mating surface in each exhaust port and entire part. Limit: Refer to " «EXHAUST MANIFOLD»(ref-516394-S03421085072012120600000) ".
2. If it exceeds the limit, replace exhaust manifold.

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1. Drain engine oil. Refer to " «DRAINING»(ref-516404-S29020311892012120600000) ".
2. Remove oil pan (lower) with the following procedure: Loosen mounting bolts in reverse order as shown in the figure. NOTE: Disregard the numerical order No. 7 and No. 11 in removal. 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 surfaces. Slide the seal cutter [SST: KV10111100 (J-37228)] by tapping on the side of tool with a hammer. Remove oil pan (lower).

Clean oil strainer if any object attached.

1. Check the engine oil level and adjust engine oil. Refer to " «INSPECTION»(ref-516404-S13780865602012120600000) ".
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 " «INSPECTION»(ref-516404-S13780865602012120600000) ".

Inspection for Leakage

The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.

1. 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 " «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-516397-S25479234352012120600000) ".
2. 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 leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. 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: Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission / transaxle fluid AT & CVT Models Leakage Level / Leakage Leakage MT Models Level / Leakage Leakage Level / Leakage Other oils and fluids (1) Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases - Leakage - (1) Power steering fluid, brake fluid, etc.

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Inspection for Leakage

The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.

1. 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 " «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-516397-S25479234352012120600000) ".
2. 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 leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. 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: Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission / transaxle fluid AT & CVT Models Leakage Level / Leakage Leakage MT Models Level / Leakage Leakage Level / Leakage Other oils and fluids (1) Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases - Leakage - (1) Power steering fluid, brake fluid, etc.

Inspection for Leakage

The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.

1. 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 " «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-516397-S25479234352012120600000) ".
2. 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 leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise will stop after hydraulic pressure rises.
4. Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. 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: Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission / transaxle fluid AT & CVT Models Leakage Level / Leakage Leakage MT Models Level / Leakage Leakage Level / Leakage Other oils and fluids (1) Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases - Leakage - (1) Power steering fluid, brake fluid, etc.

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Inspection of Camshaft Sprocket (INT), (EXH) Oil Groove

1. Check engine oil level. Refer to " «INSPECTION»(ref-516404-S13780865602012120600000) ".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. Release the fuel pressure. Refer to " «WORK PROCEDURE»(ref-516395-S28376118092012120600000) ". Remove intake manifold. Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ". Disconnect ignition coil and injector harness connectors. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting bracket (RH) and engine mounting insulator (RH). Refer to " «2WD: EXPLODED VIEW»(ref-516394-S25757987982012120600000) " (M/T models) or " «4WD (AWD): EXPLODED VIEW»(ref-516394-S39445883752012120600000) " (CVT models).
3. Remove intake or exhaust valve timing control solenoid valve. Refer to " «EXPLODED VIEW»(ref-516394-S04113068152012120600000) ". Lift the front side of the engine with a jack base to remove intake or exhaust valve timing control solenoid valve.
4. Clean the mounting area of intake or exhaust valve timing control solenoid valve, and then insert a clean waste with no oil adhesion into the oil hole of the cylinder head.
5. Install engine mounting insulator (RH) and engine mounting bracket (RH). (After the removal of intake or exhaust valve timing control solenoid valve and insertion of a waste into the oil hole.)
6. Perform cranking to check that engine oil comes out from the oil hole (mounting hole of intake or exhaust valve timing control solenoid valve) of cylinder head. Regarding the engine oil check, judge it by the amount of oil adhered to the wasted inserted into the oil hole. WARNING: Never insert fingers into the oil hole. Be careful not to touch rotating parts (drive belt, idler pulleys and crankshaft pulley, etc.). CAUTION: Never perform cranking without installing the engine mounting insulator (RH) and engine mounting bracket (RH). Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination. Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belt, engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
7. Perform the following inspection if engine oil does not come out from intake or exhaust valve timing control solenoid valve oil hole of the cylinder head. Clean oil groove between oil strainer and intake or exhaust valve timing control solenoid valve. Refer to " «ENGINE LUBRICATION SYSTEM»(ref-516404-S26979244122012120600000) " and " «ENGINE LUBRICATION SYSTEM SCHEMATIC»(ref-516404-S18517392302012120600000) ".
8. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT) or exhaust valve control solenoid valve and camshaft sprocket (EXH), and then check each oil groove for clogging. Clean oil groove if necessary. Refer to " «ENGINE LUBRICATION SYSTEM»(ref-516404-S26979244122012120600000) " and " «ENGINE LUBRICATION SYSTEM SCHEMATIC»(ref-516404-S18517392302012120600000) ".
9. After inspection, install removed parts in the reverse order.

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1. Remove camshafts. Refer to " «EXPLODED VIEW»(ref-516394-S32610026052012120600000) ".
2. Remove valve lifters. Refer to " «EXPLODED VIEW»(ref-516394-S32610026052012120600000) ".
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve from dropping into cylinder. CAUTION: When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
4. Remove valve collet. Compress valve spring with the valve spring compressor [SST: KV10116200 (J-26336-A)] (A), the attachment [SST: KV10115900 (J-26336-20)] (C), and the adapter [SST: KV10109220 (-)] (B). Remove valve collet with magnet hand. CAUTION: Be careful not to damage valve lifter holes. Fit the attachment [SST: KV10115900 (J-26336-20)] in the center of valve spring retainer to press it.
5. Remove valve spring retainer and valve spring (with valve spring seat). CAUTION: Never remove valve spring seat from valve spring.
6. Remove valve oil seal with the valve oil seal puller [SST: KV10107902 (J-38959)] (A).

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1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the height (H) shown in the figure with the valve oil seal drift [SST: KV10115600 (J-38958)] (A). Height (H): 15.1 - 15.7 mm (0.594 - 0.618 in)
3. Install in the reverse order of removal, for the rest of parts.

Inspection for Leakage

The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.

1. 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 " «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-516397-S25479234352012120600000) ".
2. 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 leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. 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: Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Transmission / transaxle fluid AT & CVT Models Leakage Level / Leakage Leakage MT Models Level / Leakage Leakage Level / Leakage Other oils and fluids (1) Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases - Leakage - (1) Power steering fluid, brake fluid, etc.

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1. Remove oil pan (lower). Refer to " «EXPLODED VIEW»(ref-516394-S21352110102012120600000) ".
2. Remove oil filter. Refer to " «REMOVAL AND INSTALLATION»(ref-516404-S34115289962012120600000) ".
3. Remove front cover, timing chain, oil pump drive chain, and other related parts. Refer to " «EXPLODED VIEW»(ref-516394-S04113068152012120600000) ".
4. Remove oil level gauge and oil level gauge guide.
5. Remove oil pump. Refer to " «EXPLODED VIEW»(ref-516404-S19006337982012120600000) ". NOTE: The oil pan (upper) can be removed and installed without removing the oil pump.
6. Remove oil pan (upper) with the following procedure: Loosen bolts in reverse order as shown in the figure. Insert a screwdriver shown by the arrow (<==) in the figure and open up a crack between oil pan (upper) and cylinder block. CAUTION: A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified. Insert seal cutter [SST: KV10111100 (J-37228)] between oil pan (upper) and cylinder block, and slide it by tapping on the side of the tool with a hammer. CAUTION: Never damage the mating surface.
7. Remove O-ring between cylinder block and oil pan (upper).

Clean oil strainer portion (part of the oil pump) if any object attached.

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1. Remove oil pan (upper). Refer to " «EXPLODED VIEW»(ref-516394-S21352110102012120600000) ".
2. Remove thermostat housing. Refer to " «EXPLODED VIEW»(ref-516398-S04589720062012120600000) ".
3. Remove knock sensor. CAUTION: Carefully handle sensor avoiding shocks.
4. 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 " «INSPECTION»(ref-516394-S05015785222012120600000) ". Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. Remove connecting rod cap. Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side. CAUTION: Never damage matching surface with connecting rod cap. Never damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
5. Remove connecting rod bearings. CAUTION: When removing them, note the installation position. Keep them in the correct.
6. Remove piston rings from piston. Before removing piston rings, check the piston ring side clearance. Refer to " «INSPECTION»(ref-516394-S05015785222012120600000) ". Use a piston ring expander (commercial service tool) (A). CAUTION: When removing piston rings, be careful not to damage the piston. Never damage piston rings by expanding them excessively.
7. Remove piston from connecting rod with the following procedure: Using snap ring pliers (A), remove snap rings. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use drier (A) or equivalent. Push out piston pin with stick of outer diameter approximately 18 mm (0.71 in).
8. Remove main bearing cap bolts. Measure crankshaft end play before loosening main bearing cap bolts. Refer to " «INSPECTION»(ref-516394-S05015785222012120600000) ". Loosen and remove main bearing cap bolts in reverse order as shown in the figure. Use TORX socket.
9. Remove main bearing caps. Tap main bearing caps lightly with a plastic hammer for removal. CAUTION: Be careful not to damage the mounting surface.
10. Remove crankshaft. CAUTION: Be careful not to damage or deform signal plate (1) mounted on rear end of crankshaft (A). 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.
11. Pull rear oil seal out from rear end of crankshaft.
12. Remove main bearings and thrust bearings from cylinder block and main bearing caps. CAUTION: Identify installation positions, and store them without mixing them up.