Juke F15 (2012 year). Service Repair Manual — part 201
EX-4
< PERIODIC MAINTENANCE >
[MR16DDT ]
EXHAUST SYSTEM
PERIODIC MAINTENANCE
EXHAUST SYSTEM
Inspection
INFOID:0000000006356455
Check exhaust pipes, muffler, and mounting for improper attach-
ment, leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.
SMA211A
EXHAUST SYSTEM
EX-5
< REMOVAL AND INSTALLATION >
[MR16DDT ]
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REMOVAL AND INSTALLATION
EXHAUST SYSTEM
Exploded View
INFOID:0000000006356456
2WD
JPBIA4322GB
1.
Center muffler
2.
Mounting rubber
3.
Spring
4.
Seal bearing
5.
Stud bolt
6.
Three way catalyst
7.
Heated oxygen sensor 2
8.
Seal bearing
9.
Ring gasket
10. Main muffler
A.
To catalyst convertor
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
EX-6
< REMOVAL AND INSTALLATION >
[MR16DDT ]
EXHAUST SYSTEM
4WD
Removal and Installation
INFOID:0000000006356457
REMOVAL
• Disconnect each joint and mounting.
• Remove heated oxygen sensor 2 with following procedure:
- Using heated oxygen sensor wrench [SST: KV10114400] (A),
removal heated oxygen sensor 2 (1).
CAUTION:
Be careful not to 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.
JPBIA4323GB
1.
Center pipe
2.
Mounting rubber
3.
Spring
4.
Seal bearing
5.
Stud bolt
6.
Three way catalyst
7.
Seal bearing
8.
Ring gasket
9.
Main muffler
A.
To catalyst convertor
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
2
: Exhaust front tube
PBIC4498J
EXHAUST SYSTEM
EX-7
< REMOVAL AND INSTALLATION >
[MR16DDT ]
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• Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a con-
crete floor. Use a new one.
• Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxy-
gen 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 sen-
sor 2, resulting in the “MIL” coming on.
• 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 mount-
ing 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.
Catalyst convertor to Exhaust Front Tube
1.
Securely insert seal bearing (2) into catalyst convertor (1).
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
2.
With spring, tighten nut.
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 (
).
3.
After installing, check that stud bolt does not interfere with mounting hole of exhaust front tube.
Exhaust Front Tube to Center Muffler
1.
Securely insert seal bearing (2) into exhaust front tube (1) side
in the direction shown in the figure.
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
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 center muffler (
).
3.
After installing, check that bolt does not interfere with mounting hole of center muffler.
Inspection
INFOID:0000000006356458
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.
3
: Spring
4
: Nut
5
: Exhaust front tube
JPBIA4440ZZ
3
: Spring
4
: Bolt
5
: Center muffler
JPBIA2174ZZ
EX-8
< REMOVAL AND INSTALLATION >
[MR16DDT ]
EXHAUST SYSTEM
• 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.
PRECAUTIONS
EX-9
< PRECAUTION >
[HR16DE]
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PRECAUTION
PRECAUTIONS
Removal and Installation
INFOID:0000000006502093
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.
EX-10
< PREPARATION >
[HR16DE]
PREPARATION
PREPARATION
PREPARATION
Special Service Tools
INFOID:0000000006502094
Commercial Service Tools
INFOID:0000000006502095
Tool number
Tool name
Description
KV10114400
Heated oxygen sensor wrench
Loosening or tightening heated oxygen sen-
sor 2
a: For 22 mm (0.87 in) width hexagon nut
S-NT636
Tool name
Description
Power tool
Loosening nuts and bolts
Heated oxygen sensor thread cleaner
Reconditioning the exhaust system threads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
A: J-43897-18 [18 mm (0.71 in) dia.] for zir-
conia heated oxygen sensor
B: J-43897-12 [12 mm (0.47 in) dia.] for tita-
nia heated oxygen sensor
C: Mating surface shave cylinder
D: Flutes
Anti-seize lubricant (Permatex 133AR
or equivalent meeting MIL specifica-
tion MIL-A-907)
Lubricating heated oxygen sensor thread
cleaner when reconditioning exhaust system
threads
PBIC0190E
JPBIA0238ZZ
AEM489
EXHAUST SYSTEM
EX-11
< PERIODIC MAINTENANCE >
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PERIODIC MAINTENANCE
EXHAUST SYSTEM
Inspection
INFOID:0000000006502096
Check exhaust pipes, muffler, and mounting for improper attach-
ment, leakage, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.
SMA211A
EX-12
< REMOVAL AND INSTALLATION >
[HR16DE]
EXHAUST SYSTEM
REMOVAL AND INSTALLATION
EXHAUST SYSTEM
Exploded View
INFOID:0000000006502097
Removal and Installation
INFOID:0000000006502098
REMOVAL
• Disconnect each joint and mounting.
• Remove heated oxygen sensor 2 with following procedure:
1.
Mounting rubber
2.
Main muffler
3.
Seal bearing
4.
Spring
5.
Mounting rubber
6.
Seal bearing
7.
Exhaust front tube
8.
Heated oxygen sensor 2
9.
Sub muffler
10. Gasket
: Always replace after every disassembly.
: N·m (kg-m, ft-lb)
JPBIA4113GB
EXHAUST SYSTEM
EX-13
< REMOVAL AND INSTALLATION >
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- Using heated oxygen sensor wrench [SST: KV10114400] (A),
removal heated oxygen sensor 2 (1).
CAUTION:
Be careful not to 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.
• Discard any heated oxygen sensor 2 which has been dropped onto a hard surface such as a con-
crete floor. Use a new one.
• Before installing a new heated oxygen sensor 2, clean exhaust system threads using the heated oxy-
gen 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 sen-
sor 2, resulting in the “MIL” coming on.
• 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 mount-
ing 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.
Exhaust Manifold to Exhaust Front Tube
1.
Securely insert seal bearing (2) into exhaust manifold (1) side in
the direction shown in the figure.
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
2.
With spring, tighten nut.
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 (
).
3.
After installing, check that stud bolt does not interfere with mounting hole of exhaust front tube.
Exhaust Front Tube to Center Muffler
JPBIA4222ZZ
3
: Spring
4
: Nut
5
: Stud bolt
6
: Exhaust front tube
JPBIA2372ZZ
EX-14
< REMOVAL AND INSTALLATION >
[HR16DE]
EXHAUST SYSTEM
1.
Securely insert seal bearing (2) into exhaust front tube (1) side
in the direction shown in the figure.
CAUTION:
Be careful not to damage seal bearing surface when install-
ing.
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 center muffler (
).
3.
After installing, check that bolt does not interfere with mounting hole of center muffler.
Inspection
INFOID:0000000006502099
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.
3
: Spring
4
: Bolt
5
: Center muffler
JPBIA2174ZZ
PRECAUTIONS
EX-15
< PRECAUTION >
[K9K]
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PRECAUTION
PRECAUTIONS
Removal and Installation
INFOID:0000000006502100
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.
EX-16
< PERIODIC MAINTENANCE >
[K9K]
EXHAUST SYSTEM
PERIODIC MAINTENANCE
EXHAUST SYSTEM
Inspection
INFOID:0000000006502101
Check exhaust pipes, muffler and mounting for improper attachment,
leaks, cracks, damage or deterioration.
• If anything is found, repair or replace damaged parts.
SMA211A
EXHAUST SYSTEM
EX-17
< REMOVAL AND INSTALLATION >
[K9K]
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REMOVAL AND INSTALLATION
EXHAUST SYSTEM
Exploded View
INFOID:0000000006502102
Removal and Installation
INFOID:0000000006502103
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 is still hot just
after the engine stops.
• Be careful not to cut your hand on the insulator edge.
REMOVAL
1.
Remove Diesel particulate filter assembly.
2.
Remove exhaust center tube and muffler from rubber mounting.
3.
Remove exhaust center tube.
4.
Remove main muffler.
Exhaust Pressure Sensor
REMOVAL
1.
Main muffler
2.
Mounting rubber
3.
Ring gasket
4.
Center tube
5.
Exhaust gas temperature sensor 2
6.
Diesel particulate filter assembly
7.
Gasket
8.
Stud bolt
9.
Diesel particulate filter inlet tube
10. Gasket
A.
To exhaust manifold
B.
To pressure hose
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
JPBIA4804GB
EX-18
< REMOVAL AND INSTALLATION >
[K9K]
EXHAUST SYSTEM
WARNING:
• Any intervention on system during product life cycle is prohibited. If an intervention is required, the
system will need to be entirely replaced.
• The pressure measurement circuit must never be opened except at the adapters on the exhaust
pipe.
• Any intervention (excluding assembly) on system and more specifically, on the connection between
stainless steel preformed tube and rubber hose is prohibited (sealing of the system would no longer
be guaranteed). For example, intervention on screw, clamp, sensor, etc..
1.
Remove engine under cover.
2.
Disconnect exhaust pressure sensor harness connector.
3.
Remove exhaust pressure sensor fixing bolt.
4.
Remove exhaust pressure hose.
INSTALLATION
• Install in the reverse order of removal.
CAUTION:
• Always replace exhaust gaskets with new ones when reassembling.
• If the insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the insula-
tor, remove them.
• When installing the insulator avoid large gaps or interference between the insulator and each
exhaust pipe.
• Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas
leakage.
• Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle
side. Check each part for unusual interference, and then tighten them to the specified torque.
• When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/left
directions.
Exhaust Pressure sensor
CAUTION:
• In case clamp has been damaged or broken, it is necessary to charge the differential assembly itself,
in order to avoid any leakage. it is not possible to replace just the clamp.
• In case it would be necessary to change the washer of the coupling nut, then the coupling nut must
be replaced itself as these two parts are an assembly part.
• Any contact of the hose with products likely to damage them should be avoided.
• The screw of the stainless steel preformed tube can only be tightened once (re-use is prohibited)
• During any handling operation of the Diesel Particulate Filter pressure measurement hoses (han-
dling, storage, assembly, etc.), the parts should never be folded or submitted to tension.
Installation is basically the reverse order of the removal.
Inspection
INFOID:0000000006502104
INSPECTION AFTER INSTALLATION
• With the engine running, check exhaust tube joints for gas leakage and unusual noises.
• Check to ensure that mounting brackets and mounting insulators are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration.
EXL-1
DRIVER CONTROLS
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CONTENTS
EXTERIOR LIGHTING SYSTEM
HALOGEN TYPE
PRECAUTION . . . . . . . . . . . ...
PRECAUTIONS . . . . . . . . . . . . ...
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect . . . . . . . . .....
SYSTEM DESCRIPTION . . . . . . . ..
COMPONENT PARTS . . . . . . . . . .
Component Parts Location . . . . . . . . . ....
Component Description . . . . . . . . . . ....
Light & Rain Sensor . . . . . . . . . . . . ..
SYSTEM . . . . . . . . . . . . . . . ..
HEADLAMP SYSTEM . . . . . . . . . . . .....
HEADLAMP SYSTEM : System Diagram . . . .....
HEADLAMP SYSTEM : System Description . . .....
HEADLAMP SYSTEM : Fail-Safe . . . . . . ...
AUTO LIGHT SYSTEM (WITHOUT DTRL) . . . ...
AUTO LIGHT SYSTEM (WITHOUT DTRL) : Sys-
tem Diagram . . . . . . . . . . . . . . .
AUTO LIGHT SYSTEM (WITHOUT DTRL) : Sys-
tem Description . . . . . . . . . . . . . ...
AUTO LIGHT SYSTEM (WITH DTRL) . . . . . ..
AUTO LIGHT SYSTEM (WITH DTRL) : System
Diagram . . . . . . . . . . . . . . . . ...
AUTO LIGHT SYSTEM (WITH DTRL) : System
Description . . . . . . . . . . . . . . . ..
DAYTIME RUNNING LIGHT SYSTEM . . . . . ..
DAYTIME RUNNING LIGHT SYSTEM : System
Diagram . . . . . . . . . . . . . . . . ...
DAYTIME RUNNING LIGHT SYSTEM : System
Description . . . . . . . . . . . . . . . ..
HEADLAMP AIMING CONTROL (MANUAL) . . ...
HEADLAMP AIMING CONTROL (MANUAL) :
System Description . . . . . . . . . . . . ..
FRONT FOG LAMP SYSTEM . . . . . . . . ...
FRONT FOG LAMP SYSTEM : System Diagram .
FRONT FOG LAMP SYSTEM : System Descrip-
tion . . . . . . . . . . . . . . . . . . ...
FRONT FOG LAMP SYSTEM : Fail-Safe . . . ...
REAR FOG LAMP SYSTEM . . . . . . . . . ..
REAR FOG LAMP SYSTEM : System Diagram . ..
REAR FOG LAMP SYSTEM : System Description .
TURN SIGNAL AND HAZARD WARNING LAMP
SYSTEM . . . . . . . . . . . . . . . . . .
TURN SIGNAL AND HAZARD WARNING LAMP
SYSTEM : System Diagram . . . . . . . . .
TURN SIGNAL AND HAZARD WARNING LAMP
SYSTEM : System Description . . . . . . . .
PARKING, LICENSE PLATE AND TAIL LAMP
SYSTEM (WITHOUT DTRL) . . . . . . . . . ..
PARKING, LICENSE PLATE AND TAIL LAMP
SYSTEM (WITHOUT DTRL) : System Diagram . ..
PARKING, LICENSE PLATE AND TAIL LAMP
SYSTEM (WITHOUT DTRL) : System Description
.
PARKING, LICENSE PLATE AND TAIL LAMP
SYSTEM (WITHOUT DTRL) : Fail-Safe . . . . ..
PARKING, LICENSE PLATE AND TAIL LAMP
SYSTEM (WITH DTRL) . . . . . . . . . . . ..
PARKING, LICENSE PLATE AND TAIL LAMP
SYSTEM (WITH DTRL) : System Diagram . . . .
PARKING, LICENSE PLATE AND TAIL LAMP
SYSTEM (WITH DTRL) : System Description . . .
PARKING, LICENSE PLATE AND TAIL LAMP
SYSTEM (WITH DTRL) : Fail-Safe . . . . . . .
EXTERIOR LAMP BATTERY SAVER SYSTEM
(WITHOUT DTRL) . . . . . . . . . . . . . ..
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