Juke F15 (2012 year). Service Repair Manual — part 232

NOISE

HA-85

< SYMPTOM DIAGNOSIS >

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NOISE

Symptom Table

INFOID:0000000006485652

Symptom

Noise source

Probable cause

Corrective action

Unusual noise from compressor
when A/C is ON.

Inside of compressor

Wear, breakage, or clogging of foreign
material in inner parts.

Check compressor oil. Re-
fer to

HA-78, "Inspection"

.

Magnet clutch

Contact of clutch disc with pulley.

Check clearance between
clutch disc and pulley. Refer
to

HA-89, "Inspection"

.

Compressor body

Loosened compressor mounting bolts.

Check bolts for tightness.
Refer to

HA-86, "Exploded

View"

.

Unusual noise from cooler piping.

Cooler piping (pipe and
flexible hose)

Improper installation of clip and brack-
et.

Check the installation condi-
tion of the cooler piping. Re-
fer to

HA-90, "Exploded

View"

.

Unusual noise from expansion
valve when A/C is ON.

Expansion valve

Shortage of refrigerant.

• Check for leakage.
• Collect all refrigerant,

evacuate refrigerant cycle
again, and then refill it
with the specified amount
of refrigerant.

Wear, breakage, or clogging of foreign
material in inner parts.

Eliminate foreign material
from expansion valve, or re-
place it.

Unusual noise from belt.

—

Loosened belt

Check belt tension. Refer to

EM-20, "Checking"

.

Internal compressor parts get locked

Replace compressor.

HA-86

< REMOVAL AND INSTALLATION >

[MR16DDT ]

COMPRESSOR

REMOVAL AND INSTALLATION

COMPRESSOR

Exploded View

INFOID:0000000006485653

REMOVAL

DISASSEMBLY

1.

High-pressure flexible hose

2.

O-ring

3.

Compressor

4.

O-ring

5.

Low-pressure flexible hose

A.

To condenser

B.

To evaporator

: N·m (kg-m, ft-lb)

JMIIA0939GB

1.

Compressor unit

2.

Field coil

3.

Snap ring

4.

Pulley assembly

5.

Snap ring

6.

Shim

7.

Clutch disc

: N·m (kg-m, ft-lb)

JMIIA0802GB

COMPRESSOR

HA-87

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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COMPRESSOR

COMPRESSOR : Removal and Installation

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CAUTION:

Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to

HA-

78, "Perform Lubricant Return Operation"

.

REMOVAL

1.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to

HA-76, "Recy-

cle Refrigerant"

.

2.

Remove drive belt. Refer to

EM-20, "Removal and Installation"

.

3.

Remove mounting bolts (A), and then disconnect low-pressure
flexible hose (1) and high-pressure flexible hose (2). (compres-
sor side)

CAUTION:

Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.

4.

Disconnect magnet clutch harness connector.

5.

Remove mounting bolts. Pull out compressor in the direction
indicated by an arrow as shown in the figure to remove.

CAUTION:

Be careful not to contact with and damage surrounding
parts when removing compressor from the vehicle.

INSTALLATION

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

CAUTION:

• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Perform lubricant adjusting procedure before installing new compressor. Refer to

HA-79, "Lubricant

Adjusting Procedure for Compressor Replacement"

.

• Check for leakages when recharging refrigerant. Refer to

HA-74, "Leak Test"

.

• Check tension of the drive belt after installing compressor. Refer to

EM-20, "Checking"

.

MAGNET CLUTCH

: Vehicle front

JMIIA0947ZZ

: Vehicle front

JMIIA0948ZZ

JMIIA1038ZZ

HA-88

< REMOVAL AND INSTALLATION >

[MR16DDT ]

COMPRESSOR

MAGNET CLUTCH : Removal and Installation of Compressor Clutch

INFOID:0000000006485655

REMOVAL

Overhaul

1.

When removing center bolt, hold clutch disc with clutch disc
wrench (SST:KV99232340) (A).

2.

Remove clutch disc.

3.

Remove snap ring using external snap ring pliers.

4.

Position center pulley puller on the end of the drive shaft, and remove pulley assembly using any commer-
cially available pulley puller.
To prevent pulley groove from being deformed, puller claws should be positioned into the edge of the pul-
ley assembly.

5.

Disconnect harness connector from compressor unit.

6.

Remove snap ring using external snap ring pliers, and then remove field coil.

INSTALLATION

1.

Install field coil (1).
Be sure to align the coil’s pin (2) with the hole in the compres-
sor’s front head.

2.

Install field coil harness clip.

3.

Install pulley assembly (1) using pulley installer
(SST:KV99106200) (A) and a hand press, and then install snap
ring (2) using snap ring pliers.

4.

Install clutch disc on drive shaft, together with original shim(s). Press clutch disc down by hand.

JMIIA0574ZZ

JMIIA0575ZZ

JMIIA0576ZZ

COMPRESSOR

HA-89

< REMOVAL AND INSTALLATION >

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5.

Tighten center bolt to the specified torque while fixing clutch disc
not to rotate using a clutch disc wrench (SST:KV99232340).
After tightening the bolt, check that the pulley rotates smoothly.

Break-in Operation

When replacing compressor clutch assembly, always perform the break-in operation, by engaging and disen-
gaging the clutch approximately 30-times. Break-in operation increases the level of transmitted torque.

Inspection

INFOID:0000000006485656

CHECK DISC TO PULLEY CLEARANCE

Check the clearance (B) between pulley assembly (1) and clutch
disc (2) along the entire periphery with a feeler gauge (A).

Replace compressor if specified clearance is not obtained.

JMIIA0577ZZ

Clearance

: Refer to

HA-118, "Compressor"

.

JPIIA1566ZZ

HA-90

< REMOVAL AND INSTALLATION >

[MR16DDT ]

COOLER PIPE AND HOSE

COOLER PIPE AND HOSE

Exploded View

INFOID:0000000006485657

HIGH-PRESSURE FLEXIBLE HOSE

HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation

INFOID:0000000006485658

CAUTION:

Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to

HA-

78, "Perform Lubricant Return Operation"

.

REMOVAL

1.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to

HA-76, "Recy-

cle Refrigerant"

.

2.

Remove front bumper fascia assembly. Refer to

EXT-13, "Removal and Installation"

.

1.

A/C unit assembly

2.

O-ring

3.

High-pressure pipe

4.

O-ring

5.

Low-pressure flexible hose

6.

High-pressure flexible hose

7.

O-ring

8.

Condenser

9.

Compressor

: Do not reuse

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

JMIIA0942GB

COOLER PIPE AND HOSE

HA-91

< REMOVAL AND INSTALLATION >

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3.

Remove mounting bolt (A), and then disconnect high-pressure
flexible hose from condenser.

CAUTION:

Cap or wrap the joint of the A/C piping and condenser with
suitable material such as vinyl tape to avoid the entry of air.

4.

Remove mounting bolt (A), and then disconnect high-pressure
flexible hose from compressor.

CAUTION:

Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.

5.

Remove high-pressure flexible hose from vehicle.

INSTALLATION

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

CAUTION:

• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to

HA-74, "Leak Test"

.

LOW-PRESSURE FLEXIBLE HOSE

LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation

INFOID:0000000006485659

CAUTION:

Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to

HA-

78, "Perform Lubricant Return Operation"

.

REMOVAL

1.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to

HA-76, "Recy-

cle Refrigerant"

.

2.

Remove front bumper fascia asembly. Refer to

EXT-13, "Removal and Installation"

.

3.

Remove cowl top extension. Refer to

EXT-20, "Removal and Installation"

.

4.

Remove mounting nut, and then move lower dash insulator
aside.

: Vehicle front

JMIIA0949ZZ

: Vehicle front

JMIIA0950ZZ

: Nut

: Vehicle front

JMIIA0973ZZ

HA-92

< REMOVAL AND INSTALLATION >

[MR16DDT ]

COOLER PIPE AND HOSE

5.

Remove mounting bolt (A), and then disconnect low-pressure
flexible hose (1) and high-pressure pipe (2) from expansion
valve. Refer to

HA-116, "EXPANSION VALVE : Removal and

Installation"

.

CAUTION:

Cap or wrap the joint of the A/C piping and expansion valve
with suitable material such as vinyl tape to avoid the entry
of air.

6.

Remove mounting bolt (A) of low-pressure flexible hose front side (1) and mounting nut (B) of low-pres-
sure flexible hose rear side (2).

7.

Remove ground wire mounting bolt (A), and then move ground
wire (1) aside.

8.

Remove mounting bolt (A), and then disconnect low-pressure
flexible hose from compressor.

CAUTION:

Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.

9.

Remove low-pressure flexible hose from vehicle.

INSTALLATION

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

CAUTION:

• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to

HA-74, "Leak Test"

.

HIGH-PRESSURE PIPE

: Vehicle front

JMIIA0974ZZ

: Vehicle front

JMIIA0972ZZ

: Vehicle front

JMIIA0977ZZ

: Vehicle front

JMIIA0971ZZ

COOLER PIPE AND HOSE

HA-93

< REMOVAL AND INSTALLATION >

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HIGH-PRESSURE PIPE : Removal and Installation

INFOID:0000000006485660

CAUTION:

Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to

HA-

78, "Perform Lubricant Return Operation"

.

REMOVAL

1.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to

HA-76, "Recy-

cle Refrigerant"

.

2.

Remove low-pressure flexible hose. Refer to

HA-91, "LOW-PRESSURE FLEXIBLE HOSE : Removal and

Installation"

.

3.

Remove mounting bolt (A), and then disconnect high-pressure
pipe (1) from condenser.

CAUTION:

Cap or wrap the joint of the A/C piping and condenser with
suitable material such as vinyl tape to avoid the entry of air.

4.

Remove high-pressure pipe (1) fixing clips (B), and then remove
high-pressure pipe from vehicle.

INSTALLATION

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

CAUTION:

• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to

HA-74, "Leak Test"

.

: Vehicle front

JMIIA0975ZZ

: Vehicle front

JMIIA0976ZZ

HA-94

< REMOVAL AND INSTALLATION >

[MR16DDT ]

CONDENSER

CONDENSER

Exploded View

INFOID:0000000006485661

CONDENSER

CONDENSER : Removal and Installation

INFOID:0000000006485662

CAUTION:

Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to

HA-

78, "Perform Lubricant Return Operation"

.

REMOVAL

1.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to

HA-76, "Recy-

cle Refrigerant"

.

2.

Remove front bumper fascia assembly. Refer to

EXT-13, "Removal and Installation"

.

3.

Remove air guide (LH). Refer to

DLK-149, "MR16DDT : Exploded View"

.

4.

Disconnect refrigerant pressure sensor harness connector.

1.

Condenser

2.

Condenser lower bracket RH

3.

Condenser lower bracket LH

4.

O-ring

5.

Liquid tank braket

6.

Liquid tank

7.

Braket

8.

O-ring

9.

Refrigerant pressure sensor

: Do not reuse

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

JMIIA0946GB

CONDENSER

HA-95

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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5.

Remove mounting bolt (A), and then disconnect high-pressure
pipe (1) from condenser.

CAUTION:

Cap or wrap the joint of the A/C piping and condenser with
suitable material such as vinyl tape to avoid the entry of air.

6.

Remove mounting bolt (A), and then disconnect high-pressure
flexible hose from condenser.

CAUTION:

Cap or wrap the joint of the A/C piping and condenser with
suitable material such as vinyl tape to avoid the entry of air.

7.

Remove mounting bolts, and then remove condenser from the vehicle.

CAUTION:

Be careful not to damage core surface of condenser.

INSTALLATION

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

CAUTION:

• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Perform lubricant adjusting procedure before installing new condenser. Refer to

HA-79, "Lubricant

Adjusting Procedure for Compressor Replacement"

.

• Check for leakages when recharging refrigerant. Refer to

HA-74, "Leak Test"

.

LIQUID TANK

LIQUID TANK : Removal and Installation

INFOID:0000000006485663

CAUTION:

Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to

HA-

78, "Perform Lubricant Return Operation"

.

REMOVAL

1.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to

HA-76, "Recy-

cle Refrigerant"

.

2.

Remove front bumper fascia assembly. Refer to

EXT-13, "Removal and Installation"

.

3.

Remove air guide (LH). Refer to

DLK-149, "MR16DDT : Exploded View"

.

4.

Clean liquid tank and its surrounding area, and then remove dust and rust from liquid tank.

5.

Diconnect refrigerant pressure sensor harness connector.

6.

Remove mounting bolts, and then remove liquid tank from condenser.

CAUTION:

Cap or wrap the joint of the A/C piping and liquid tank with suitable material such as vinyl tape to
avoid the entry of air.

INSTALLATION

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

CAUTION:

: Vehicle front

JMIIA0975ZZ

: Vehicle front

JMIIA0949ZZ

HA-96

< REMOVAL AND INSTALLATION >

[MR16DDT ]

CONDENSER

• Replace O-rings of the A/C piping with new ones. Then apply compressor oil to them when installing.
• Perform lubricant adjusting procedure before installing new liquid tank. Refer to

HA-79, "Lubricant

Adjusting Procedure for Compressor Replacement"

.

• Check for leakages when recharging refrigerant. Refer to

HA-74, "Leak Test"

.

REFRIGERANT PRESSURE SENSOR

REFRIGERANT PRESSURE SENSOR : Removal and Installation

INFOID:0000000006485664

CAUTION:

Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to

HA-

78, "Perform Lubricant Return Operation"

.

REMOVAL

1.

Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to

HA-76, "Recy-

cle Refrigerant"

.

2.

Remove front bumper fascia. Refer to

EXT-13, "Removal and Installation"

.

3.

Clean refrigerant pressure sensor and its surrounding area, and then remove dust and rust from refriger-
ant pressure sensor.

4.

Disconnect refrigerant pressure sensor connector.

5.

Use a adjustable wrench or other tool to hold the refrigerant pressure sensor mounting block, and then
remove the refrigerant pressure sensor from condenser.

CAUTION:

• Be careful not to damage core surface of condenser.
• Cap or wrap the joint of the condenser and liquid tank with suitable material such as vinyl tape to

avoid the entry of air.

INSTALLATION

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

CAUTION:

• Replace O-ring with new one. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to

HA-74, "Leak Test"

.

A/C UNIT ASSEMBLY

HA-97

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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A/C UNIT ASSEMBLY

Exploded View (Automatic Air Conditioning)

INFOID:0000000006607840

REMOVAL

LHD models (4WD)

DISASSEMBLY

JMIIA0943GB

1.

A/C unit assembly

2.

Drain hose

3.

Steering member

4.

Instrument stay

: Clip

: N·m (kg-m, ft-lb)

HA-98

< REMOVAL AND INSTALLATION >

[MR16DDT ]

A/C UNIT ASSEMBLY

LHD models (4WD)

JMIIA0982GB

1.

Ventilator seal

2.

Defroster seal

3.

Upper attachment case

4.

Sub defroster door

5.

Center ventilator and defroster door

6.

Side ventilator seal LH

7.

Lower attachment case

8.

Side ventilator seal RH

9.

Sub harness

10. Power transistor

11.

Upper intake case

12. Intake door

13. Lower intake case

14.

Blower case LH

15. Blower case RH

16. Blower motor

17.

Intake seal

18. A/C unit case RH

19. Air conditioner filter

20.

Filter cover

21. Case packing

22. Intake sensor

23.

Evaporator

24. Plate

25. Expansion valve grommet

26.

O-ring

27. Expansion valve

28. Evaporator cover

29.

Heater hose

30. Clamp

31. Heater pipe grommet

32.

Heater pipe support

33. Heater core

34. A/C unit case LH

35.

Aspirator duct

36. Aspirator

37. Foot door

38.

Foot door rod

39. Side ventilator door

40. Air mix door guide

41.

Upper air mix door

42. Lower air mix door

A.

To water outlet

A/C UNIT ASSEMBLY

HA-99

< REMOVAL AND INSTALLATION >

[MR16DDT ]

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REMOVAL

RHD models (4WD)

DISASSEMBLY

: Do not reuse

: N·m (kg-m, in-lb)

JMIIA0890GB

1.

A/C unit assembly

2.

Drain hose

3.

Steering member

4.

Instrument stay

: Clip

: N·m (kg-m, ft-lb)

HA-100

< REMOVAL AND INSTALLATION >

[MR16DDT ]

A/C UNIT ASSEMBLY

RHD models (4WD)

JMIIA0984GB

1.

Ventilator seal

2.

Defroster seal

3.

Upper attachment case

4.

Sub defroster door

5.

Center ventilator and defroster door

6.

Side ventilator seal LH

7.

Lower attachment case

8.

Side ventilator seal RH

9.

Sub harness

10. Power transistor

11.

Upper intake case

12. Intake door

13. Lower intake case

14.

Blower case LH

15. Blower case RH

16. Blower motor

17.

Intake seal

18. A/C unit case RH

19. Case packing

20.

Intake sensor

21. Evaporator

22. Plate

23.

Expansion valve grommet

24. O-ring

25. Expansion valve

26.

Evaporator cover

27. Heater hose

28. Clamp

29.

Heater pipe grommet

30. Heater pipe support

31. Filter cover

32.

Air conditioner filter

33. Heater core

34. A/C unit case LH

35.

Aspirator

36. Aspirator duct

37. Foot door

38.

Foot door rod

39. Side ventilator door

40. Air mix door guide

41.

Upper air mix door

42. Lower air mix door

A.

To water outlet