Juke F15 (2012 year). Service Repair Manual — part 57
CO-28
< REMOVAL AND INSTALLATION >
[MR16DDT ]
WATER OUTLET
• Place a thread (A) so that it is caught in the valves of water control
valve (1). Immerse fully in a container (B) filled with water. Heat
while stirring.
• The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
• Continue heating. Check the continuous valve lifting toward maxi-
mum valve lift.
NOTE:
The maximum valve lift amount standard temperature for water
control valve is the reference value.
• After checking the maximum valve lift amount, lower the water
temperature and check the valve closing temperature.
• If out of the standard, replace water control valve.
INSPECTION AFTER INSTALLATION
• Check for leakage of engine coolant using the radiator cap tester adapter (commercial service tool) and the
radiator cap tester (commercial service tool). Refer to
• Start and warm up the engine. Check visually that there is no leakage of engine coolant.
Standard:
Refer to
.
PBIC3314J
SERVICE DATA AND SPECIFICATIONS (SDS)
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< SERVICE DATA AND SPECIFICATIONS (SDS)
[MR16DDT ]
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Periodical Maintenance Specification
INFOID:0000000006356337
ENGINE COOLANT CAPACITY (APPROXIMATE)
Unit:
(Imp qt)
Radiator
INFOID:0000000006356338
Unit: kPa (kg/cm
2
, psi)
Thermostat
INFOID:0000000006356339
Standard
Water Control Valve
INFOID:0000000006356340
Standard
Engine coolant capacity (With reservoir tank at “MAX” level)
CVT models
8.1 (7-1/8)
M/T models
Reservoir tank engine coolant capacity (At “MAX” level)
0.6 (1/2)
Cap relief pressure
Standard
78 - 98 (0.8 - 1.0, 11 - 14)
Limit
59 (0.6, 9)
Leakage testing pressure
98 (1.0, 14)
Valve opening temperature
80.5 - 83.5
°
C (177 - 182
°
F)
Maximum valve lift
8.0 mm/95
°
C (0.315 in/203
°
F)
Valve closing temperature
77
°
C (171
°
F)
Valve opening temperature
93.5 - 96.5
°
C (200 - 206
°
F)
Maximum valve lift
8.0 mm/108
°
C (0.315 in/226
°
F)
Valve closing temperature
90
°
C (194
°
F)
CO-30
< PRECAUTION >
[HR16DE]
PRECAUTIONS
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"
INFOID:0000000006752513
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
The vehicle may be equipped with a passenger air bag deactivation switch. Because no rear seat exists where
a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a
rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the
instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is
enabled and could inflate for certain types of collision. When the switch is turned to the OFF position, the pas-
senger air bag is disabled and will not inflate. A passenger air bag OFF indicator on the instrument panel lights
up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected
by the passenger air bag deactivation switch.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIR BAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
• The vehicle may be equipped with a passenger air bag deactivation switch which can be operated by
the customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and
will not inflate. When the passenger air bag is switched ON, the passenger air bag is enabled and
could inflate for certain types of collision. After SRS maintenance or repair, make sure the passenger
air bag deactivation switch is in the same position (ON or OFF) as when the vehicle arrived for ser-
vice.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect
INFOID:0000000006492569
NOTE:
• Before removing and installing any control units, first turn the ignition switch to the LOCK position, then dis-
connect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.
PRECAUTIONS
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< PRECAUTION >
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OPERATION PROCEDURE
1.
Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2.
Turn the ignition switch to ACC position.
(At this time, the steering lock will be released.)
3.
Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4.
Perform the necessary repair operation.
5.
When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
6.
Perform self-diagnosis check of all control units using CONSULT-III.
CO-32
< PREPARATION >
[HR16DE]
PREPARATION
PREPARATION
PREPARATION
Commercial Service Tools
INFOID:0000000006492570
Tool name
Description
Radiator cap tester
Checking radiator and radiator cap
Radiator cap tester adapter
Adapting radiator cap tester to radiator cap
and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
PBIC1982E
S-NT564
DESCRIPTION
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< SYSTEM DESCRIPTION >
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SYSTEM DESCRIPTION
DESCRIPTION
Engine Cooling System
INFOID:0000000006492571
JPBIA4754GB
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< SYSTEM DESCRIPTION >
[HR16DE]
DESCRIPTION
Engine Cooling System Schematic
INFOID:0000000006492572
M/T models
CVT models
JPBIA3129GB
JPBIA4756GB
OVERHEATING CAUSE ANALYSIS
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< SYMPTOM DIAGNOSIS >
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SYMPTOM DIAGNOSIS
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart
INFOID:0000000006492573
Symptom
Check items
Cooling sys-
tem parts
malfunction
Poor heat transfer
Water pump malfunction
Worn or loose drive belt
—
Thermostat and water con-
trol valve stuck closed
—
Damaged fins
Dust contamination or pa-
per clogging
Physical damage
Clogged radiator cooling
tube
Excess foreign material
(rust, dirt, sand, etc.)
Reduced air flow
Cooling fan does not oper-
ate
Fan assembly
—
High resistance to fan rota-
tion
Damaged fan blades
Damaged radiator shroud
—
—
—
Improper engine coolant
mixture ratio
—
—
—
Poor engine coolant quality
—
Engine coolant viscosity
—
Insufficient engine coolant
Engine coolant leakage
Cooling hose
Loose clamp
Cracked hose
Water pump
Poor sealing
Radiator cap
Loose
Poor sealing
Radiator
O-ring for damage, deterio-
ration or improper fitting
Cracked radiator tank
Cracked radiator core
Reservoir tank
Cracked reservoir tank
Overflowing reservoir tank
Exhaust gas leakage into
cooling system
Cylinder head deterioration
Cylinder head gasket deteri-
oration
CO-36
< SYMPTOM DIAGNOSIS >
[HR16DE]
OVERHEATING CAUSE ANALYSIS
Except cool-
ing system
parts mal-
function
—
Overload on engine
Abusive driving
High engine rpm under no
load
Driving in low gear for ex-
tended time
Driving at extremely high
speed
Power train system mal-
function
—
Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flow
Blocked bumper
—
—
Blocked radiator grille
Installed car brassiere
Mud contamination or paper
clogging
Blocked radiator
—
Blocked condenser
Blocked air flow
Installed large fog lamp
Symptom
Check items
ENGINE COOLANT
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< PERIODIC MAINTENANCE >
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PERIODIC MAINTENANCE
ENGINE COOLANT
Inspection
INFOID:0000000006492574
LEVEL
• Check that the reservoir tank engine coolant level is within the
“MIN” to “MAX” when the engine is cool.
• Adjust the engine coolant level if necessary.
LEAKAGE
• To check for leakage, apply pressure to the cooling system with the
radiator cap tester (commercial service tool) (A) and the radiator
cap tester adapter (commercial service tool) (B).
WARNING:
Never remove radiator cap when engine is hot. Serious burns
may occur from high-pressure engine coolant escaping from
radiator.
CAUTION:
Higher test pressure than specified may cause radiator dam-
age.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.
• If anything is found, repair or replace damaged parts.
Draining
INFOID:0000000006492575
WARNING:
• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine
coolant escaping from radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres-
sure. Then turn it all the way.
1.
Remove engine under cover.
2.
Open radiator drain plug (A) at the bottom of radiator, and then
remove radiator cap.
CAUTION:
Perform this step when engine is cold.
• When draining all of engine coolant in the system, open water
drain plugs on cylinder block. Refer to
3.
Remove reservoir tank if necessary, and drain engine coolant and clean reservoir tank before installing.
Refer to
A
: MAX
B
: MIN
JPBIA0102ZZ
Testing pressure: Refer to
PBIC5121J
: Vehicle front
JPBIA4207ZZ
CO-38
< PERIODIC MAINTENANCE >
[HR16DE]
ENGINE COOLANT
4.
Check drained engine coolant for contaminants such as rust, corrosion or discoloration. If contaminated,
flush the engine cooling system. Refer to
.
Refilling
INFOID:0000000006492576
1.
Install reservoir tank if removed and radiator drain plug.
CAUTION:
Be sure to clean drain plug and install with new O-ring.
• If water drain plugs on cylinder block are removed, close and tighten them. Refer to
.
2.
Check that each hose clamp has been firmly tightened.
3.
Remove air duct (between air cleaner case and electric throttle control actuator). Refer to
4.
Disconnect heater hose (1) at position (
) in the figure.
• Enhance heater hose as high as possible.
5.
Fill radiator (1) to specified level.
CAUTION:
Never adhere the engine coolant to electronic equipments
(alternator etc.).
• Pour coolant slowly of less than 2 (2-1/8 US qt, 1-3/4
Imp qt) a minute to allow air in system to escape.
• When engine coolant overflows disconnected heater
hose, connect heater hose, and continue filling the engine
coolant.
• Use Genuine NISSAN Engine Coolant or equivalent in its
quality mixed with water (distilled or demineralized). Refer
to
MA-13, "Fluids and Lubricants"
.
6.
Refill reservoir tank to “MAX” level line with engine coolant.
7.
Install air duct (between air cleaner case and electric throttle control actuator). Refer to
Radiator drain plug
: Refer to
: Vehicle front
JPBIA4208ZZ
Engine coolant capacity
(With reservoir tank at “MAX” level)
Refer to
CO-54, "Periodical Maintenance Specifica-
.
JPBIA0819ZZ
A
: MAX
B
: MIN
Reservoir tank engine coolant capacity
(At “MAX” level)
Refer to
CO-54, "Periodical Maintenance Specification"
JPBIA0102ZZ
ENGINE COOLANT
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< PERIODIC MAINTENANCE >
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8.
Install radiator cap.
9.
Warm up engine until opening thermostat. Standard for warming-up time is approximately 10 minutes at
3,000 rpm.
• Check thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.
CAUTION:
Watch water temperature gauge so as not to overheat engine.
10. Stop the engine and cool down to less than approximately 50
°
C (122
°
F).
• Cool down using fan to reduce the time.
• If necessary, refill radiator up to filler neck with engine coolant.
CAUTION:
Never adhere the engine coolant to electronic equipments (alternator etc.).
11. Refill reservoir tank to “MAX” level line with engine coolant.
12. Repeat steps 5 through 10 two or more times with radiator cap installed until engine coolant level no
longer drops.
13. Check cooling system for leakage with engine running.
14. Warm up the engine, and check for sound of engine coolant flow while running engine from idle up to
3,000 rpm with heater temperature controller set at several position between “COOL” and “WARM”.
• Sound may be noticeable at heater unit.
15. Repeat step 14 three times.
16. If sound is heard, bleed air from cooling system by repeating step 5 through 10 until reservoir tank level no
longer drops.
Flushing
INFOID:0000000006492577
1.
Install reservoir tank if removed and radiator drain plug.
CAUTION:
Be sure to clean drain plug and install with new O-ring.
• If water drain plugs on cylinder block are removed, close and tighten them. Refer to
2.
Remove air duct (between air cleaner case and electric throttle control actua-
tor). Refer to .
3.
Disconnect heater hose (1) at position (
) in the figure.
• Enhance heater as high as possible.
4.
Fill radiator and reservoir tank with water and reinstall radiator cap.
• When engine coolant over flows disconnected heater hose, connect heater hose, and continue filling the
engine coolant.
5.
Install air duct (between air cleaner case and electric throttle control actuator). Refer to
6.
Run the engine and warm it up to normal operating temperature.
7.
Rev the engine two or three times under no-load.
8.
Stop the engine and wait until it cools down.
9.
Drain water from the system. Refer to
10. Repeat steps 1 through 9 until clear water begins to drain from radiator.
Radiator drain plug
: Refer to
: Vehicle front
JPBIA4208ZZ
CO-40
< PERIODIC MAINTENANCE >
[HR16DE]
RADIATOR
RADIATOR
RADIATOR CAP
RADIATOR CAP : Inspection
INFOID:0000000006492578
• Check valve seat (A) of radiator cap.
- Check that valve seat is swollen to the extent that the edge of the
plunger cannot be seen when watching it vertically from the top.
- Check that valve seat has no soil and damage.
• Pull negative-pressure valve to open it, and that it close completely
when released.
- Check that there is no dirt or damage on the valve seat of radiator
cap negative-pressure valve.
- Check that there are no unusualness in the opening and closing
conditions of negative-pressure valve.
• Check radiator cap relief pressure.
- When connecting radiator cap to the radiator cap tester (commer-
cial service tool) (A) and the radiator cap tester adapter (commer-
cial service tool) (B), apply engine coolant to the cap seal surface.
• Replace radiator cap if there is an unusualness related to the above three.
CAUTION:
When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue
or foreign material.
RADIATOR
RADIATOR : Inspection
INFOID:0000000006492579
Check radiator for mud or clogging. If necessary, clean radiator as follows.
CAUTION:
• Be careful not to bend or damage radiator fins.
• When radiator is cleaned without removal, remove all surrounding parts such as radiator cooling fan
assembly and horns. Then tape harness and harness connectors to prevent water from entering.
1.
Apply water by hose to the back side of the radiator core vertically downward.
2.
Apply water again to all radiator core surfaces once per minute.
3.
Stop washing if any stains no longer flow out from radiator.
B : Metal plunger
JPBIA0108ZZ
SMA967B
Standard and Limit
: Refer to
PBIC5122J
RADIATOR
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< PERIODIC MAINTENANCE >
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4.
Blow air into the back side of radiator core vertically downward.
• Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm
2
, 71 psi) and keep distance more than 30 cm
(11.81 in).
5.
Blow air again into all the radiator core surfaces once per minute until no water sprays out.
CO-42
< REMOVAL AND INSTALLATION >
[HR16DE]
RADIATOR
REMOVAL AND INSTALLATION
RADIATOR
Exploded View
INFOID:0000000006492580
Removal and Installation
INFOID:0000000006492581
REMOVAL
WARNING:
• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine
coolant escaping from radiator.
• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres-
sure. Then turn it all the way.
1.
Drain engine coolant from radiator. Refer to
.
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.
1.
Reservoir tank hose
2.
Mounting rubber (upper)
3.
Radiator tank cap
4.
Radiator 5.
Mounting
rubber
(lower)
6.
O-ring
7.
Drain plug
8.
Clamp
9.
Radiator hose (lower)
10. Cooling fan assembly
11.
Radiator hose (upper)
12. Reservoir tank
13. Reservoir tank cap
A.
To water outlet
B.
To water inlet
C.
To water inlet
: Always replace after every disassembly.
: N·m (kg-m, in-lb)
JPBIA4103ZZ
RADIATOR
CO-43
< REMOVAL AND INSTALLATION >
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2.
Remove air duct (inlet). Refer to
.
3.
Remove reservoir tank as follows:
a.
Disconnect reservoir tank hose.
b.
Release the tab (A) in the direction shown by the arrow (
).
c.
Lift up and remove the reservoir tank with tab released.
4.
Remove radiator hose (upper and lower).
5.
Disconnect harness connector from fan motor, and move harness aside.
6.
Remove cooling fan assembly.
CAUTION:
Be careful not to damage or scratch the radiator core.
7.
Remove the following parts.
• Front grille assembly. Refer to
EXT-18, "Removal and Installation"
.
• Front bumper fasica assembly. Refer to
EXT-13, "Removal and Installation"
• Front combination lamp assembly (LH and RH). Refer to
EXL-91, "Removal and Installation"
8.
Remove radiator core support (upper). Refer to
DLK-147, "HR16DE : Removal and Installation"
(WITH I-
KEY &SUPER LOCK) or
DLK-310, "HR16DE : Removal and Installation"
(WITH I-KEY WITHOUT SUPER
DLK-445, "HR16DE : Removal and Installation"
(WITHOUT I-KEY &WITH SUPER LOCK)
561, "HR16DE : Removal and Installation"
9.
Remove the radiator (1) from bottom of the vehicle.
CAUTION:
Be careful not to damage radiator core and condenser assembly core.
INSTALLATION
Install in the reverse order of removal.
Radiator
NOTE:
When installing radiator core support (upper), check that both upper and lower mounts of radiator and air con-
ditioner condenser are inserted in the mounting holes of radiator core support (upper, lower).
CAUTION:
Use genuine mounting bolts for the cooling fan assembly and strictly observe the tightening torque.
(Breakage prevention for radiator)
Reservoir tank
NOTE:
• Insert reservoir tank straight into the mounting location and check by the feel that the pawl is securely fas-
tened.
• Pull reservoir tank upward to check that it does not come off.
Radiator hose
NOTE:
Insert the radiator hose (1) all the way to the stopper (2) or by 33 mm (1.30 in) (hose without a stopper).
JPBIA4209ZZ
2
: Condenser assembly
: Vehicle front
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