ENGINE

CONTENTS

Model: MR16DDT

• PRECAUTION .............................................. 2
• PRECAUTIONS .................................................. 2
• Precautions for Removing Battery Terminal ............2
• Removal and Installation ..........................................2
• PREPARATION ........................................... 3
• Special Service Tools ...............................................3
• Commercial Service Tools .......................................3
• PERIODIC MAINTENANCE ........................ 4
• EXHAUST SYSTEM ........................................... 4
• Inspection ................................................................ 4
• REMOVAL AND INSTALLATION ............... 5
• EXHAUST SYSTEM ........................................... 5
• Exploded View .........................................................5
• Removal and Installation ......................................... 8
• Inspection ...............................................................11

Revision: 2014 February

Vehicle: 2013 JUKE

PRECAUTION

PRECAUTIONS

Precautions for Removing Battery Terminal

• When removing the 12V battery terminal, turn OFF the ignition switch and wait at least 30 seconds.

ℹ️ 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.

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

ℹ️ NOTE: If the ignition switch is turned ON with any one of the terminals of the main battery and sub battery disconnected, then DTC may be detected.

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

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

Diagram Description: A simple line drawing shows a car battery with positive (+) and negative (-) terminals, and a cable connected to the negative terminal.

Removal and Installation

⚠️ CAUTION:

• Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance, and shape.
• Perform the operation with the exhaust system fully cooled down because the system will be hot just after engine stops.
• Be careful not to cut your hand on the heat insulator edge.

PREPARATION

Special Service Tools

Tool Name: Heated oxygen sensor wrench

Tool Number (TechMateNo.): KV10114400 (J-38365)

Description: Loosening or tightening heated oxygen sensor 2 (2WD models). Specifically designed for a 22 mm (0.87 in) width hexagon nut.

Diagram Description: An illustration shows a specialized wrench with a hexagonal opening, designed to fit over an oxygen sensor. It indicates the size 'a' for a 22 mm hexagon nut.

Commercial Service Tools

Power tool

Description: Loosening nuts and bolts.

Diagram Description: An illustration of an impact wrench or similar power tool used for fastening and unfastening nuts and bolts.

Heated oxygen sensor thread cleaner

Description: Reconditioning the exhaust system threads before installing a new heated oxygen sensor. Use with anti-seize lubricant.

• A: J-43897-18 [18 mm (0.71 in) dia.] for zirconia heated oxygen sensor
• B: J-43897-12 [12 mm (0.47 in) dia.] for titania heated oxygen sensor
• C: Mating surface shave cylinder
• D: Flutes

Diagram Description: Illustrations show the heated oxygen sensor thread cleaner components. Part A and B show different sized cleaning heads. Part C shows a cylindrical tool, and Part D indicates fluted edges.

Anti-seize lubricant

Description: Lubricating heated oxygen sensor thread cleaner when reconditioning exhaust system threads.

Specification: Permatex 133AR or equivalent meeting MIL specification MIL-A-907.

Diagram Description: An illustration of a bottle containing lubricant.

PERIODIC MAINTENANCE

EXHAUST SYSTEM Inspection

• Check exhaust pipes, muffler, and mounting for improper attachment, leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.

Diagram Description: A simplified diagram of an exhaust system, showing the exhaust pipe, muffler, and mounting points. It highlights areas to check for issues.

REMOVAL AND INSTALLATION

EXHAUST SYSTEM

Exploded View (2WD Standard models)

Diagram Description: An exploded view diagram illustrates the assembly of the exhaust system for 2WD Standard models. Components are numbered and shown in their relative positions.

Components:

1. Center muffler
2. Mounting rubber
3. Spring
4. Seal bearing
5. Stud bolt
6. Exhaust front tube
7. Heated oxygen sensor 2
8. Seal bearing
9. Ring gasket
10. Main muffler
11. A: To catalyst convertor

Specifications:

• [Torque: N·m (kg-m, ft-lb)]
• [Replace after disassembly]

Exploded View (2WD NISMO models)

Diagram Description: An exploded view diagram illustrates the assembly of the exhaust system for 2WD NISMO models. Components are numbered and shown in their relative positions.

Components:

1. Center muffler
2. Mounting rubber
3. Spring
4. Seal bearing
5. Stud bolt
6. Exhaust front tube
7. Heated oxygen sensor 2
8. Seal bearing
9. Ring gasket
10. Main muffler
11. A: To catalyst convertor

Specifications:

• [Torque: N·m (kg-m, ft-lb)]
• [Replace after disassembly]

Exploded View (AWD Standard models)

Diagram Description: An exploded view diagram illustrates the assembly of the exhaust system for AWD Standard models. Components are numbered and shown in their relative positions.

Components:

1. Center pipe
2. Mounting rubber
3. Spring
4. Seal bearing
5. Stud bolt
6. Exhaust front tube
7. Seal bearing
8. Ring gasket
9. Main muffler
10. A: To catalyst convertor

Specifications:

• [Torque: N·m (kg-m, ft-lb)]
• [Replace after disassembly]

Exploded View (AWD NISMO models)

Diagram Description: An exploded view diagram illustrates the assembly of the exhaust system for AWD NISMO models. Components are numbered and shown in their relative positions.

Components:

1. Center pipe
2. Mounting rubber
3. Spring
4. Seal bearing
5. Stud bolt
6. Exhaust front tube
7. Seal bearing
8. Ring gasket
9. Main muffler
10. A: To catalyst convertor

Specifications:

• [Torque: N·m (kg-m, ft-lb)]
• [Replace after disassembly]

Removal and Installation Procedures

REMOVAL

• Disconnect each joint and mounting.
• Remove heated oxygen sensor 2 using the following procedure (2WD models):
• Using heated oxygen sensor wrench [SST: KV10114400 (J-38365)] (A), remove heated oxygen sensor 2 (1).

⚠️ CAUTION: Never damage heated oxygen sensor 2.

INSTALLATION

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

⚠️ CAUTION: Always replace seal bearings with new ones when reassembling.

Diagram Description: An illustration shows the process of removing a heated oxygen sensor from an exhaust pipe using a specialized wrench.

Detailed Installation Steps and Precautions

• Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a concrete floor. Use a new one.
• Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxygen sensor thread cleaner [commercial service tool: J-43897-18 or J-43897-12] and apply anti-seize lubricant (commercial service tool).
• Never over-torque heated oxygen sensor 2. Doing so may cause damage to the heated oxygen sensor 2, resulting in the "MIL” coming on.
• Prevent rust preventives from adhering to the sensor body.
• If heat insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the heat insulator, remove them.
• When installing heat insulator, avoid large gaps or interference between heat insulator and each exhaust pipe.
• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas leakage.
• When installing each mounting rubber, use silicon oil to avoid twisting.
• Temporarily tighten mounting nuts and bolts. Check each part for unusual interference and mounting rubber interference, and then tighten them to the specified torque.
• When installing each mounting rubber, avoid twisting or unusual extension in up/down, front/rear and right/left directions.
• Install seal bearing according to the following instructions.

⚠️ CAUTION: The structure of seal bearing depends on the mounting portion. When installing seal bearings, be careful not to install the wrong one.

Seal Bearing Identification:

• A: Exhaust manifold side
• B: Mesh
• C: Exhaust front tube side
• D: Pawl (projection)

Diagram Description: Illustrations show the structure of a seal bearing with labels A, B, C, and D indicating different parts or sides. Another diagram shows the assembly of the exhaust manifold to the exhaust front tube.

Exhaust Manifold to Exhaust Front Tube Assembly

1. Place a piece of wood (A) on seal bearing (2) and securely insert the seal bearing on the exhaust manifold (1) side, using a plastic hammer (B).

⚠️ CAUTION:

• Never damage the seal bearing surface during insertion.
• If seal bearing is inserted by hammering directly without using a piece of wood, the seal bearing is deformed and exhaust gas leaks. To insert seal bearing, always use a piece of wood and insert straight.

Diagram Description: An illustration shows a seal bearing being inserted into an exhaust manifold component using a piece of wood and a hammer.

2. Check that seal bearing (1) is in absolute contact (C) with the flange (A). If there is clearance (B), insert seal bearing straight by hand to bring the seal bearing into absolute contact with the flange.

⚠️ CAUTION:

• Never use a tool for insertion.
• Never insert seal bearing by tightening exhaust front tube.

Diagram Description: Diagrams illustrate checking the seal bearing's contact with a flange. One shows a gap (B), and another shows proper contact (C).

3. With spring (3), tighten nut (4).

Component References:

• 1: Exhaust manifold
• 2: Seal bearing
• 3: Spring
• 4: Bolt
• 5: Stud bolt
• 6: Exhaust front tube

⚠️ CAUTION:

• Fasten stud bolts to the flange of exhaust manifold side to the specified torque before fastening mounting nuts.
• Ensure springs are seated correctly on the flange and not sitting on (A).
• Be careful that stud bolt does not interfere with mounting hole of exhaust front tube.

4. After installing, check that stud bolt does not interfere with mounting hole of exhaust front tube.

Diagram Description: An illustration shows the assembly of the exhaust manifold to the exhaust front tube, indicating the placement of the seal bearing, spring, and bolts/nuts.

Exhaust Front Tube to Main Muffler Assembly

1. Securely insert seal bearing (2) into exhaust front tube (1) side in the direction as shown in the figure.

Component References:

• 1: Exhaust front tube
• 2: Seal bearing
• 3: Spring
• 4: Bolt
• 5: Main muffler

⚠️ CAUTION: Be careful not to damage seal bearing surface when installing.

2. With spring, tighten bolt.

⚠️ CAUTION:

• Ensure springs are seated correctly on the flange and not sitting on (A).
• Be careful that bolt does not interfere with mounting hole of main muffler.

3. After installing, check that bolt does not interfere with mounting hole of main muffler.

Diagram Description: An illustration shows the assembly of the exhaust front tube to the main muffler, indicating the seal bearing, spring, and bolt.

Main Muffler to Post Muffler Assembly

1. Securely insert seal bearing (2) into main muffler (1) side in the direction as shown in the figure.

Component References:

• 1: Main muffler
• 2: Seal bearing
• 3: Spring
• 4: Bolt
• 5: Post muffler

⚠️ CAUTION: Be careful not to damage seal bearing surface when installing.

2. With spring, tighten bolt.

⚠️ CAUTION:

• Ensure springs are seated correctly on the flange and not sitting on (A).
• Be careful that bolt does not interfere with mounting hole of post muffler.

3. After installing, check that bolt does not interfere with mounting hole of post muffler.

Diagram Description: An illustration shows the assembly of the main muffler to the post muffler, indicating the seal bearing, spring, and bolt.

REMOVAL AND INSTALLATION

Inspection (After Installation)

• Check clearance between tail tube and rear bumper is even.
• With engine running, check exhaust tube joints for gas leakage and unusual noises.
• Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue stress. Improper installation could result in excessive noise and vibration.