Juke F15 (2012 year). Service Repair Manual — part 42

SENSOR ROTOR

BRC-229

< REMOVAL AND INSTALLATION >

[WITH ESP]

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SENSOR ROTOR

FRONT SENSOR ROTOR

FRONT SENSOR ROTOR : Removal and Installation

INFOID:0000000006601937

REMOVAL

Replace wheel hub as an assembly when replacing because sensor rotor cannot be disassembled.
• MR16DDT: Refer to

FAX-11, "Removal and Installation"

.

• HR16DE: Refer to

FAX-43, "Removal and Installation"

.

• K9K: Refer to

FAX-68, "Removal and Installation"

.

INSTALLATION

Replace wheel hub as an assembly when replacing because sensor rotor cannot be disassembled.
• MR16DDT: Refer to

FAX-11, "Removal and Installation"

.

• HR16DE: Refer to

FAX-43, "Removal and Installation"

.

• K9K: Refer to

FAX-68, "Removal and Installation"

.

REAR SENSOR ROTOR

REAR SENSOR ROTOR : Removal and Installation

INFOID:0000000006601938

REMOVAL

2WD

Replace wheel hub as an assembly when replacing because sensor rotor cannot be disassembled. Refer to

RAX-5, "Removal and Installation"

.

4WD

1.

Remove drive shaft. Refer to

RAX-17, "Removal and Installation"

.

2.

Remove sensor rotor from drive shaft. Refer to

RAX-21, "FINAL DRIVE SIDE : Disassembly and Assem-

bly"

.

INSTALLATION

Note the following, and install in the reverse order of the removal.
• Never reuse sensor rotor. (4WD)

BRC-230

< REMOVAL AND INSTALLATION >

[WITH ESP]

ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

Exploded View

INFOID:0000000006601939

LHD

MR16DDT (2WD), HR16DE

JSFIA0604GB

1.

ABS actuator and electric unit (con-
trol unit)

2.

ABS actuator and electric unit (con-
trol unit) harness connector

3.

Bracket

A.

To front LH caliper

B.

To rear RH caliper

C.

To rear LH caliper

D.

To front RH caliper

E.

To master cylinder secondary side

F.

To master cylinder primary side

: Vehicle front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

BRC-231

< REMOVAL AND INSTALLATION >

[WITH ESP]

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MR16DDT (4WD)

JSFIA0545GB

1.

ABS actuator and electric unit (con-
trol unit)

2.

ABS actuator and electric unit (con-
trol unit) harness connector

3.

Bracket

A.

To front LH caliper

B.

To rear RH caliper

C.

To rear LH caliper

D.

To front RH caliper

E.

To master cylinder secondary side

F.

To master cylinder primary side

: Vehicle front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

BRC-232

< REMOVAL AND INSTALLATION >

[WITH ESP]

ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

K9K

RHD

JSFIA0546GB

1.

ABS actuator and electric unit (con-
trol unit)

2.

ABS actuator and electric unit (con-
trol unit) harness connector

3.

Bracket

A.

To front LH caliper

B.

To rear RH caliper

C.

To rear LH caliper

D.

To front RH caliper

E.

To master cylinder secondary side

F.

To master cylinder primary side

: Vehicle front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

BRC-233

< REMOVAL AND INSTALLATION >

[WITH ESP]

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Removal and Installation

INFOID:0000000006601940

REMOVAL

1.

Disconnect battery cable from negative terminal.

2.

Drain brake fluid.
• LHD: Refer to

BR-12, "Draining"

.

• RHD: Refer to

BR-80, "Draining"

.

3.

Remove air cleaner case and air duct. (RHD) Refer to

EM-161, "Removal and Installation"

.

4.

Disconnect ABS actuator and electric unit (control unit) harness
connector (1), follow the procedure described below.

a.

Push the pawl (A).

b.

Move the lever (B) in the direction (C) until locked.

c.

Disconnect ABS actuator and electric unit (control unit) harness
connector.

5.

Loosen flare nut of brake tube using a flare nut wrench, and then
remove brake tube from ABS actuator and electric unit (control
unit).
• LHD Refer to

BR-24, "FRONT : Exploded View"

.

• RHD Refer to

BR-91, "FRONT : Exploded View"

.

6.

Remove ABS actuator and electric unit (control unit) and bracket.

CAUTION:

1.

ABS actuator and electric unit (con-
trol unit)

2.

ABS actuator and electric unit (con-
trol unit) harness connector

3.

Bracket

A.

To master cylinder secondary side

B.

To master cylinder primary side

C.

To front LH caliper

D.

To rear RH caliper

E.

To rear LH caliper

F.

To front RH caliper

: Vehicle front

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

JPFIC0193GB

JPFIC0194ZZ

BRC-234

< REMOVAL AND INSTALLATION >

[WITH ESP]

ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)

• Never remove and never install ABS actuator and electric unit (control unit) by holding harness

connector.

• Be careful not to drop ABS actuator and electric unit (control unit) and apply excessive impact to

it.

7.

Remove bracket and bushing from ABS actuator and electric unit (control unit).

INSTALLATION

Note the following, and install in the reverse order of removal.
• When replacing with a new ABS actuator and electric unit (control unit), never remove the protector of the

brake tube mounting hole until right before the brake tube is installed.

• When installing brake tube, tighten to the specified torque using a flare nut torque wrench so that flare nut

and brake tube are not damaged.

- LHD: Refer to

BR-24, "FRONT : Exploded View"

.

- RHD: Refer to

BR-91, "FRONT : Exploded View"

.

• Never remove and install ABS actuator and electric unit (control unit) by holding actuator harness.
• Bleed air from brake piping after installation.
- LHD: Refer to

BR-13, "Bleeding Brake System"

.

- RHD: Refer to

BR-81, "Bleeding Brake System"

.

• Never apply excessive impact to actuator, such as by dropping it.
• After installing the ABS actuator and electric unit (control unit) har-

ness connector (1), move the lever (A) in the direction (B) to
secure the locking.

JPFIC0195ZZ

YAW RATE/SIDE/DECEL G SENSOR

BRC-235

< REMOVAL AND INSTALLATION >

[WITH ESP]

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YAW RATE/SIDE/DECEL G SENSOR

Exploded View

INFOID:0000000006387485

Removal and Installation

INFOID:0000000006387486

REMOVAL

CAUTION:

Never drop or strike yaw rate/side/decel G sensor, because it has little endurance to impact. Never use
a pneumatic tool.

1.

Remove front seat (right side).
• 2WD: Refer to

SE-19, "Removal and Installation"

.

• 4WD: Refer to

SE-27, "Removal and Installation"

.

2.

Remove floor carpet. Refer to

INT-23, "Removal and Installation"

.

3.

Disconnect yaw rate/side/decel G sensor harness connector.

4.

Remove yaw rate/side/decel G sensor.

INSTALLATION

Note the following, and install in the reverse order of removal.
• Never drop or strike yaw rate/transverse/decel G sensor, because it has little endurance to impact. Never

use a power tool.

1.

Yaw rate/side/decel G sensor

2.

Yaw rate/side/decel G sensor har-
ness connector

3.

Bracket

: Vehicle front

: N·m (kg-m, in-lb)

JSFIA0544GB

BRC-236

< REMOVAL AND INSTALLATION >

[WITH ESP]

STEERING ANGLE SENSOR

STEERING ANGLE SENSOR

Removal and Installation

INFOID:0000000006387487

REMOVAL

1.

Remove spiral cable assembly. Refer to

SR-16, "Removal and Installation"

.

2.

Remove steering angle sensor.

INSTALLATION

Note the following, and install in the reverse order of removal.
• Perform steering angle sensor neutral position adjustment when steering angle sensor is removed and

installed, or replaced. Refer to

BRC-149, "Work Procedure"

.

ESP OFF SWITCH

BRC-237

< REMOVAL AND INSTALLATION >

[WITH ESP]

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ESP OFF SWITCH

Removal and Installation

INFOID:0000000006387488

REMOVAL

1.

Remove lower instrument panel. Refer to

IP-13, "Removal and Installation"

.

2.

Remove ESP OFF switch.

INSTALLATION

Installation is the reverse order of removal.

BRM-1

BODY EXTERIOR, DOORS, ROOF & VEHICLE SECURITY

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SECTION

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CONTENTS

BODY REPAIR

VEHICLE INFORMATION . . . . . . . .

3

BODY EXTERIOR PAINT COLOR . . . . . .

3

Body Exterior Paint Color . . . . . . . . . . ..

3

PRECAUTION . . . . . . . . . . . ...

5

REPAIRING HIGH STRENGTH STEEL . . . ..

5

High Strength Steel (HSS) . . . . . . . . . ..

5

Handling of Ultra High Strength Steel Plate Parts

. ..

8

PREPARATION . . . . . . . . . . .

9

REPAIRING MATERIAL . . . . . . . . . .

9

Foam Repair . . . . . . . . . . . . . . .....

9

BODY COMPONENT PARTS . . . . . . .

11

Underbody Component Parts (2WD Models) . . ..

11

Underbody Component Parts (4WD Models) . . ..

13

Body Component Parts (2WD Models) . . . . ...

15

Body Component Parts (4WD Models) . . . . ...

18

REMOVAL AND INSTALLATION . . . ...

21

CORROSION PROTECTION . . . . . . . .

21

Description . . . . . . . . . . . . . . . ..

21

Anti-corrosive Wax . . . . . . . . . . . . ..

21

Undercoating (2WD Models) . . . . . . . . ...

22

Undercoating (4WD Models) . . . . . . . . ...

23

Body Sealing (2WD RHD Models) . . . . . . ..

24

Body Sealing (2WD LHD Models) . . . . . . ...

28

Body Sealing (4WD RHD Models) . . . . . . ..

31

Body Sealing (4WD LHD Models) . . . . . . ...

34

BODY CONSTRUCTION . . . . . . . . .

37

Body Construction (RHD Models) . . . . . . ...

37

Body Construction (LHD Models) . . . . . . .

39

Rear Fender Hemming Process . . . . . . . ..

40

REPLACEMENT OPERATIONS . . . . . .

42

Description . . . . . . . . . . . . . . . ..

42

Radiator Core Support . . . . . . . . . . .

44

Hoodledge (RHD Models) . . . . . . . . . ...

44

Hoodledge (LHD Models) . . . . . . . . . .

45

Hoodledge (RHD Models Partial Replacement) . ..

46

Hoodledge (LHD Models Partial Replacement) . ...

48

Front Side Member (2WD, RHD Models) . . . .

50

Front Side Member (2WD, LHD Models) . . . . .

53

Front Side Member (4WD, RHD Models) . . . .

56

Front Side Member (4WD, LHD Models) . . . . .

58

Front Side Member (2WD Models Partial Replace-
ment) . . . . . . . . . . . . . . . . . ...

60

Front Side Member (4WD Models Partial Replace-
ment) . . . . . . . . . . . . . . . . . ...

62

Front Pillar (RHD Models) . . . . . . . . . ...

64

Front Pillar (LHD Models) . . . . . . . . . .

67

Center Pillar (2WD Models) . . . . . . . . . .

71

Center Pillar (4WD Models) . . . . . . . . . .

73

Outer Sill (Partial Replacement) . . . . . . . ..

75

Outer Sill (RHD Models) . . . . . . . . . . ..

76

Outer Sill (LHD Models) . . . . . . . . . . ...

79

Inner Sill . . . . . . . . . . . . . . . . ...

81

Rear Fender (2WD Models) . . . . . . . . .

84

Rear Fender (4WD Models) . . . . . . . . .

87

Rear Fender Extension (2WD Models) . . . . .

90

Rear Fender Extension (4WD Models) . . . . .

91

Rear Pillar Reinforcement . . . . . . . . . ...

91

Outer Rear Wheelhouse (2WD Models) . . . . ..

92

Outer Rear Wheelhouse (4WD Models) . . . . ..

94

Inner Rear Wheelhouse (2WD Models) . . . . ...

96

Inner Rear Wheelhouse (4WD Models) . . . . ...

97

Rear Panel (2WD Models) . . . . . . . . . ...

99

Rear Panel (4WD Models) . . . . . . . . . .

100

Inner Rear Pillar . . . . . . . . . . . . . .

100

Rear Floor Rear (2WD Models) . . . . . . . .

101

Rear Floor Rear (4WD Models) . . . . . . . .

102

Rear Side Member (4WD Models Partial Replace-
ment) . . . . . . . . . . . . . . . . . .

103

Rear Side Member Extension (2WD Models) . .

104

Rear Side Member Extension (4WD Models) . .

105

Roof . . . . . . . . . . . . . . . . . ...

107

Roof Rail . . . . . . . . . . . . . . . .

108

BRM-2

SERVICE DATA AND SPECIFICATIONS
(SDS) . . . . . . . . . . . . . . ..

109

BODY ALIGNMENT . . . . . . . . . . .

109

Body Center Marks (RHD Models) . . . . . .

109

Body Center Marks (LHD Models) . . . . . . .

110

Description . . . . . . . . . . . . . . . .

111

Engine Compartment (2WD RHD Models) . . .

111

Engine Compartment (2WD LHD Models) . . . .

114

Engine Compartment (4WD RHD Models) . . .

116

Engine Compartment (4WD LHD Models) . . .

118

Underbody (2WD Models) . . . . . . . . .

120

Underbody (4WD Models) . . . . . . . . .

122

Passenger Compartment . . . . . . . . . ..

125

Rear Body . . . . . . . . . . . . . . .

127

LOCATION OF PLASTIC PARTS . . . . .

129

Precautions for Plastics . . . . . . . . . .

129

Location of Plastic Parts . . . . . . . . . ...

130

BODY EXTERIOR PAINT COLOR

BRM-3

< VEHICLE INFORMATION >

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VEHICLE INFORMATION

BODY EXTERIOR PAINT COLOR

Body Exterior Paint Color

INFOID:0000000006482807

FOR 2WD MODELS

NOTE:

• S: Solid

• 2S: Solid + Clear

• CS: Color clear solid

• M: Metallic

• P: 2-Coat pearl

• 3P: 3-Coat pearl

• FPM: Iron oxide pearl

• RPM: Multi flex color

Component

Color code

B326

BKAD

BKAX

BKY0

BNAH

BRAQ

BZ11

Description

White

Gray

Dark Gray

Silver

Red

Dark Blue

Black

Paint type

Note

Solid

M

PM

M

PM

M

PM

Hard clear
coat

−

×

×

×

×

×

×

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Front
grille

Grille

Material color

−

−

−

−

−

−

−

Molding

Chromium
plate

Cr

Cr

Cr

Cr

Cr

Cr

Cr

2

Front bumper fascia

Body color

B326

BKAD

BKAX

BKY0

BNAH

BRAQ

BZ11

3

Front fillet molding

Material color

−

−

−

−

−

−

−

4

Door outside mirror

Body color

B326

BKAD

BKAX

BKY0

BNAH

BRAQ

BZ11

Material color

−

−

−

−

−

−

−

5

Back door finisher

Body color

B326

BKAD

BKAX

BKY0

BNAH

BRAQ

BZ11

6

Rear bumper fascia

Body color

B326

BKAD

BKAX

BKY0

BNAH

BRAQ

BZ11

7

Rear fillet molding

Material color

−

−

−

−

−

−

−

8

Center mudguard

Material color

−

−

−

−

−

−

−

9

Front door outside
handle

Body color

B326

BKAD

BKAX

BKY0

BNAH

BRAQ

BZ11

Material color

−

−

−

−

−

−

−

10

Rear door outside
handle

Material color

−

−

−

−

−

−

−

JSKIA2126ZZ

BRM-4

< VEHICLE INFORMATION >

BODY EXTERIOR PAINT COLOR

• TM: Micro titanium metallic

• PM: Pearl metallic

FOR 4WD MODELS

NOTE:

• S: Solid

• 2S: Solid + Clear

• CS: Color clear solid

• M: Metallic

• P: 2-Coat pearl

• 3P: 3-Coat pearl

• FPM: Iron oxide pearl

• RPM: Multi flex color

• TM: Micro titanium metallic

• PM: Pearl metallic

Component

Color code

BB20

BKAD

BKAX

BKY0

BNAH

BRAQ

BQX1

Description

Bluish

Black

Gray

Dark Gray

Silver

Red

Dark Blue

White

Paint type

Note

P

M

PM

M

PM

M

3P

Hard clear
coat

×

−

×

−

×

×

−

1

Front
grille

Grille

Material color

−

−

−

−

−

−

−

Molding

Chromium
plate

Cr

Cr

Cr

Cr

Cr

Cr

Cr

2

Front bumper fascia

Body color

BB20

BKAD

BKAX

BKY0

BNAH

BRAQ

BQX1

3

Front fillet molding

Material color

−

−

−

−

−

−

−

4

Door outside mirror

Body color

BB20

BKAD

BKAX

BKY0

BNAH

BRAQ

BQX1

Material color

−

−

−

−

−

−

−

5

Back door finisher

Body color

BB20

BKAD

BKAX

BKY0

BNAH

BRAQ

BQX1

6

Rear bumper fascia

Body color

BB20

BKAD

BKAX

BKY0

BNAH

BRAQ

BQX1

7

Rear fillet molding

Material color

−

−

−

−

−

−

−

8

Center mudguard

Material color

−

−

−

−

−

−

−

9

Front door outside
handle

Body color

BB20

BKAD

BKAX

BKY0

BNAH

BRAQ

BQX1

Material color

−

−

−

−

−

−

−

10

Rear door outside
handle

Material color

−

−

−

−

−

−

−

JSKIA2126ZZ

REPAIRING HIGH STRENGTH STEEL

BRM-5

< PRECAUTION >

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PRECAUTION

REPAIRING HIGH STRENGTH STEEL

High Strength Steel (HSS)

INFOID:0000000006482809

High strength steel is used for body panels in order to reduce vehicle weight.
Accordingly, precautions in repairing automotive bodies made of high strength steel are described below:

FOR 2WD MODELS

FOR 4WD MODELS

Tensile strength

Major applicable parts

440 - 780 MPa

• Trans control reinforcement

(Center front floor component part)

• Rear side member front extension

(Front floor component part)

• Inner sill
• Side dash
• Lower dash crossmember
• Front strut housing
• Front side member assembly
• Front side member closing plate assembly
• Rear seat crossmember reinforcement

(Center rear crossmember assembly component part)

• Rear side member
• Inner side roof rail
• Upper inner front pillar
• Inner center pillar
• Outer side roof rail reinforcement
• Lower center pillar brace
• Outer front pillar reinforcement

(Front pillar brace component part)

• Lower front pillar hinge brace
• Outer sill reinforcement
• Inner rear pillar reinforcement
• Front roof rail
• Rear bumper stay assembly

980 - 1310 MPa

• Lower dash crossmember (Upper)

(Lower dash component part)

• Inner center front bumper reinforcement
• Inner center rear bumper reinforcement

BRM-6

< PRECAUTION >

REPAIRING HIGH STRENGTH STEEL

Read the following precautions when repairing HSS:

1.

Additional points to consider
• The repair of reinforcements (such as side members) by heat-

ing is not recommended, because it may weaken the compo-
nent. When heating is unavoidable, never heat HSS parts
above 550

°

C (1,022

°

F).

Verify heating temperature with a thermometer.
(Crayon-type and other similar type thermometer are appropri-
ate.)

• When straightening body panels, use caution in pulling any

HSS panel. Because HSS is very strong, pulling may cause
deformation in adjacent sections of the body. In this case,
increase the number of measuring points, and carefully pull
the HSS panel.

Tensile strength

Major applicable parts

440 - 780 MPa

• Trans control reinforcement

(Center front floor component part)

• 2nd crossmember

(Front floor component part)

• Inner sill
• Side dash
• Lower dash crossmember
• Front strut housing
• Front side member assembly
• Front side member closing plate assembly
• Front suspension mounting bracket (Front)
• Rear seat crossmember
• Rear seat crossmember reinforcement

(Center rear crossmember assembly component part)

• Rear side member
• Front side member front assembly
• Inner side roof rail
• Upper inner front pillar
• Inner center pillar
• Outer side roof rail reinforcement
• Lower center pillar brace
• Outer front pillar reinforcement

(Front pillar brace component part)

• Lower front pillar hinge brace
• Outer sill reinforcement
• Inner rear pillar reinforcement
• Front roof rail
• Rear bumper stay assembly

980 - 1310 MPa

• Rear front side member extension

(Front floor component part)

• Lower dash crossmember (Upper)

(Lower dash component part)

• Inner center front bumper reinforcement
• Inner center rear bumper reinforcement

PIIA0115E

PIIA0116E

REPAIRING HIGH STRENGTH STEEL

BRM-7

< PRECAUTION >

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• When cutting HSS panels, avoid gas (torch) cutting if possible.

Instead, use a saw to avoid weakening surrounding areas due
to heat. If gas (torch) cutting is unavoidable, allow a minimum
margin of 50 mm (1.97in).

• When welding HSS panels, use spot welding whenever possi-

ble in order to minimize weakening surrounding areas due to
heat.
If spot welding is impossible, use MIG. welding. Do not use
gas (torch) for welding because it is inferior in welding
strength.

• Spot welding on HSS panels is harder than that of an ordinary

steel panel.
Therefore, when cutting spot welds on a HSS panel, use a low
speed high torque drill (1,000 to 1,200 rpm) to increase drill bit
durability and facilitate the operation.

2.

Precautions in spot welding HSS
This work should be performed under standard working condi-
tions. Always note the following when spot welding HSS:
• The electrode tip diameter must be sized properly according to

the metal thickness.

PIIA0117E

JSKIA0082GB

PIIA0145E

PIIA0146E