Juke F15 (2012 year). Service Repair Manual — part 220

FL-54

< REMOVAL AND INSTALLATION >

[K9K]

FUEL LEVEL SENSOR UNIT

• Visually confirm that the two tabs are connected to the connector.
• Pull (A) the tube and the connector to check they are securely

connected.

1

: Quick connector

JPBIA2893ZZ

FUEL TANK

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< REMOVAL AND INSTALLATION >

[K9K]

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FUEL TANK

Exploded View

INFOID:0000000006500729

Removal and Installation

INFOID:0000000006500730

WARNING:

Be sure to read “General Precautions” when working on the fuel system. Refer to

FL-45, "General Pre-

cautions"

.

REMOVAL

• Drain fuel from fuel tank if necessary. Refer to

FL-51, "Removal and Installation"

.

• Perform work on level place.
1.

Remove RH rear wheel.

2.

Perform steps 1 to 7 of

FL-51, "Exploded View"

in “FUEL LEVEL SENSOR UNIT”.

3.

Remove center muffler. Refer to

EX-17, "Exploded View"

.

4.

Remove insulator on vehicle side located above center muffler.

JPBIA3087GB

1.

Fuel tank cap

2.

Grommet

3.

Fuel filler tube

4.

Clamp

5.

Fuel filler hose

6.

Clamp

7.

Vent hose

8.

Fuel tank

9.

Mounting band (RH)

10. Mounting band (LH)

: N·m (kg-m, ft-lb)

FL-56

< REMOVAL AND INSTALLATION >

[K9K]

FUEL TANK

5.

Move parking brake cable (1) from the lower face of fuel tank.
Then remove clips for parking brake cable.

6.

Disconnect fuel filler hose at fuel tank side.

7.

Remove vent hose at RH rear wheelwell side.

8.

Support the center part of fuel tank (1) with transmission jack
(A).

CAUTION:

Securely support the fuel tank with a piece of wood (B).

9.

Remove fuel tank mounting bands (RH/LH).

10. Lower transmission jack carefully to remove fuel tank while holding it by hand.

CAUTION:

Fuel tank may be in an unstable condition because of the shape of fuel tank bottom. Never rely on
jack too much. Be sure to hold tank securely.

INSTALLATION

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

Fuel Tank

1.

Temporarily tighten bolts [except (2)] in numerical order as
shown in the figure.

2.

Tighten bolt (2) to specified torque, pressing fuel tank in the
direction (

) shown in the figure.

3.

Tighten bolts [except (2)] to specified torque in the reverse order
as shown in the figure.

Fuel Filler Hose

• Surely clamp fuel hose insert fuel filler hose to the length below.

JPBIA2896ZZ

1

: Filler tube

2

: Vent hose

3

: Filler hose

A

: Quick connector

JPBIA3026ZZ

PBIC3792E

A

: Under view

: Vehicle front

JPBIA3027ZZ

FUEL TANK

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[K9K]

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• Be sure hose clamp is not placed on swelled area of fuel filler tube.
• Install fuel filler hose to fuel tank, paying attention to install mark.

Marking faces downward.

• Tighten fuel filler hose clamp so that the remaining length of screw thread becomes to the following.

Vent Tube

1.

Check connections for damage or foreign material.

2.

Align the matching side connection part with the center of shaft, and insert connector straight until it clicks.

3.

After connecting, pull out quick connector and centralized under
floor piping by hand. Check connections are secure.

Inspection

INFOID:0000000006500731

INSPECTION AFTER INSTALLATION

Make sure there is no fuel leakage at connections in the following procedure.
• Start engine, rev it up and make sure there is no fuel leakage at connections.

Fuel filler hose

: 35 mm (1.38 in)

The other hose

: 25 mm (0.98 in)

MBIB9043E

Fuel filler tube side

: 8 - 12 mm (0.28 - 0.43 in)

Fuel tank side

: 5 - 9 mm (0.25 - 0.35 in)

A

: Pull

JPBIA0140ZZ

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< SERVICE DATA AND SPECIFICATIONS (SDS)

[K9K]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

Fuel tank

INFOID:0000000006500732

Fuel tank capacity

Approx. 52

(10-1/8 Imp gal)

Fuel recommendation

Refer to

GI-35, "Fuel"

.

FSU-1

SUSPENSION

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SECTION

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CONTENTS

FRONT SUSPENSION

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

2

PRECAUTIONS . . . . . . . . . . . . ...

2

Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" . . . . . . . . . . . . . . . . ...

2

Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect . . . . . . . . .....

2

Precautions for Suspension . . . . . . . . . ..

3

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

4

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

4

Special Service Tools . . . . . . . . . . . ....

4

Commercial Service Tools . . . . . . . . . ....

4

SYMPTOM DIAGNOSIS . . . . . . . ...

5

NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING . . . . . . . .

5

NVH Troubleshooting Chart . . . . . . . . . ..

5

PERIODIC MAINTENANCE . . . . . . ..

6

FRONT SUSPENSION ASSEMBLY . . . . ...

6

Inspection . . . . . . . . . . . . . . . . ..

6

WHEEL ALIGNMENT . . . . . . . . . . ..

7

Inspection . . . . . . . . . . . . . . . . ..

7

REMOVAL AND INSTALLATION . . . .

9

FRONT COIL SPRING AND STRUT . . . . .

9

Exploded View . . . . . . . . . . . . . . ..

9

Removal and Installation . . . . . . . . . . .

10

Disassembly and Assembly . . . . . . . . . .

10

Inspection . . . . . . . . . . . . . . . .

12

Disposal . . . . . . . . . . . . . . . . ...

12

TRANSVERSE LINK . . . . . . . . . . .

14

Exploded View . . . . . . . . . . . . . . .

14

Removal and Installation . . . . . . . . . . .

14

Inspection . . . . . . . . . . . . . . . .

14

FRONT STABILIZER . . . . . . . . . .

16

Exploded View . . . . . . . . . . . . . . .

16

Removal and Installation . . . . . . . . . . .

16

Inspection . . . . . . . . . . . . . . . .

17

FRONT SUSPENSION MEMBER . . . . . .

18

Exploded View . . . . . . . . . . . . . . .

18

Removal and Installation . . . . . . . . . . .

18

Inspection . . . . . . . . . . . . . . . .

19

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

21

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

21

Wheel Alignment . . . . . . . . . . . . . .

21

Ball Joint . . . . . . . . . . . . . . . . ..

22

Wheelarch Height . . . . . . . . . . . . .

22

FSU-2

< PRECAUTION >

PRECAUTIONS

PRECAUTION

PRECAUTIONS

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"

INFOID:0000000006752397

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:0000000006752398

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

FSU-3

< 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.

Precautions for Suspension

INFOID:0000000006545064

• After servicing suspension parts, be sure to check wheel alignment.
• Self-lock nuts are not reusable. Always use new ones when installing. Since new self-lock nuts are pre-oiled,

tighten as they are.

• The tightening surface must be kept free of oil/grease.
• When jacking up the vehicle with a floor jack, never hang the jack on the torque rod.

FSU-4

< PREPARATION >

PREPARATION

PREPARATION

PREPARATION

Special Service Tools

INFOID:0000000006545065

Commercial Service Tools

INFOID:0000000006545066

Tool number
Tool name

Description

KV991040S1
1. KV99104020 Adapter A
2. KV99104030 Adapter B
3. KV99104040 Adapter C
4. KV99104050 Adapter D
5. KV99104060 Plate
6. KV99104070 Guide bolt
7. KV99104080 Spring
8. KV99104090 Center plate

Measuring wheel alignment

ST35652000
Strut attachment

Disassembling and assembling strut

ZZA1167D

ZZA0807D

Tool name

Description

Spring compressor

Removing and installing coil spring

S-NT717

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

FSU-5

< SYMPTOM DIAGNOSIS >

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SYMPTOM DIAGNOSIS

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NVH Troubleshooting Chart

INFOID:0000000006545067

Use chart below to find the cause of the symptom. If necessary, repair or replace these parts.

×

: Applicable

Reference page

FSU-9

,

FSU-1

4

,

FSU-1

6

,

FSU-1

8

FS

U-12

—

—

—

FSU-9

,

FSU-1

4

,

FSU-1

6

,

FSU-1

8

FS

U-

7

FS

U-16

NVH in

F

AX

and FS

U sections

NVH in WT

section

NVH in WT

section

NVH in F

A

X section

NVH in BR

section

NVH in ST

section

Possible cause and SUSPECTED PARTS

Im

pro

per in

st

a

lla

ti

on

,

lo

os

en

es

s

Sh

oc

k ab

so

rbe

r de

fo

rma

tio

n,

da

ma

ge

or de

fl

e

c

ti

on

Bu

sh

in

g o

r

m

o

u

n

ti

ng

de

te

ri

ora

ti

o

n

Part

s interference

S

p

ring

fa

tig

u

e

Su

sp

en

si

on

lo

os

en

es

s

Inc

o

rrec

t whe

e

l al

ig

nm

en

t

S

ta

b

iliz

er ba

r

fa

tig

u

e

FRONT AXLE AND F

R

ONT

SUSPENSI

ON

TIRE

R

O

AD

W

H

EE

L

DRIVE SHA

F

T

BRAKE

STEERI

N

G

Symptom

FRONT SUSPENSION

Noise

×

×

×

×

×

×

×

×

×

×

×

×

Shake

×

×

×

×

×

×

×

×

×

×

×

Vibration

×

×

×

×

×

×

×

×

×

Shimmy

×

×

×

×

×

×

×

×

×

×

Judder

×

×

×

×

×

×

×

×

Poor quality ride or
handling

×

×

×

×

×

×

×

×

×

×

FSU-6

< PERIODIC MAINTENANCE >

FRONT SUSPENSION ASSEMBLY

PERIODIC MAINTENANCE

FRONT SUSPENSION ASSEMBLY

Inspection

INFOID:0000000006545068

COMPONENT PART

Check the mounting conditions (looseness, backlash) of each component and component conditions (wear,
damage) are normal.

BALL JOINT AXIAL END PLAY

1.

Set front wheels in a straight-ahead position.

2.

Measure axial end play by prying it up/down with iron bar or equivalent between transverse link and steer-
ing knuckle.

CAUTION:

• Never depress brake pedal when measuring.
• Never perform with tires on level ground.
• Be careful not to damage ball joint boot. Never damage the installation position by applying

excessive force.

STRUT ASSEMBLY

Check for oil leakage, damage, and replace if necessary.

Axial end play

: Refer to

FSU-22, "Ball Joint"

.

WHEEL ALIGNMENT

FSU-7

< PERIODIC MAINTENANCE >

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WHEEL ALIGNMENT

Inspection

INFOID:0000000006545069

DESCRIPTION

CAUTION:

• The adjustment mechanisms of camber, caster, and kingpin inclination angles are not included.
• If camber, caster, or kingpin inclination angle is outside the standard, check front suspension parts

for wear and damage. Replace suspect parts if a malfunction is detected.

• Kingpin inclination angle is reference value, no inspection is required.
Measure wheel alignment under unladen conditions.
NOTE:
“Unladen conditions” means that fuel, engine coolant, and lubricant are full. Spare tire, jack, hand tools and
mats are in designated positions.

PRELIMINARY CHECK

Check the following:
• Tires for improper air pressure and wear.
• Road wheels for runout. Refer to

WT-7, "Inspection"

.

• Wheel bearing axial end play. Refer to

FAX-9, "Inspection"

.

• Transverse link ball joint axial end play. Refer to

FSU-14, "Inspection"

.

• Strut operation.
• Each mounting part of axle and suspension for looseness and deformation.
• Each of suspension member, strut and transverse link for cracks, deformation and other damage.
• Vehicle height (posture).

CAMBER, CASTER, AND KINGPIN INCLINATION ANGLES

Before inspection, mount front wheels onto turning radius gauge. Mount rear wheels onto a stand at the same
height so that vehicle remains horizontal.

Using a CCK Gauge

Install the CCK gauge attachment (SST: KV991040S1) with the following procedure on wheel, then measure
wheel alignment.

1.

Remove three wheel to nuts, and install the guide bolts to hub
bolt.

2.

Screw the adapter into the plate until it contacts the plate tightly.

3.

Screw the center plate into the plate.

4.

Insert the plate assembly on the guide bolt. Put the spring in,
and then evenly screw the three guide bolt nuts. When fastening
the guide nuts, do not completely compress the spring.

5.

Place the dent of alignment gauge onto the projection of the
center plate and tightly contact them to measure.

CAUTION:

• If camber, caster, or kingpin inclination angle exceeds the

standard value, check front suspension parts for wear and
damage. Replace suspect parts if a malfunction is
detected.

• Kingpin inclination angle is reference value, no inspection

is required.

TOE-IN

Measure toe-in by the following procedure.

SEIA0240E

Camber, caster, kingpin
inclination angles

: Refer to

FSU-21, "Wheel

Alignment"

.

SEIA0241E

FSU-8

< PERIODIC MAINTENANCE >

WHEEL ALIGNMENT

WARNING:

• Always perform the following procedure on a flat surface.
• Check that no person is in front of vehicle before pushing it.

1.

Bounce front of vehicle up and down to stabilize the vehicle height (posture).

2.

Push vehicle straight ahead about 5 m (16 ft).

3.

Put matching mark (A) on base line of the tread (rear side) of
both tires at the same height of hub center. These are measur-
ing points.

4.

Measure distance (A) (rear side).

5.

Push vehicle slowly ahead to rotate wheels 180 degrees (1/2
turn).
NOTE:
If the wheels rotates more than 180 degrees (1/2 turn), start this
procedure again from the beginning. Do not push the vehicle
backward.

6.

Measure distance (B) (front side).

• If toe-in exceeds the standard value, adjust toe-in by varying the length of between steering outer socket

and inner socket.

JPEIA0014ZZ

: Vehicle front

Total toe-in = A – B

Total toe-in

: Refer to

FSU-21, "Wheel Alignment"

.

JPEIA0015ZZ

FRONT COIL SPRING AND STRUT

FSU-9

< REMOVAL AND INSTALLATION >

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REMOVAL AND INSTALLATION

FRONT COIL SPRING AND STRUT

Exploded View

INFOID:0000000006545070

2WD

4WD

JPEIA0269GB

1.

Piston rod lock nut

2.

Mounting insulator

3.

Mounting bearing

4.

Bound bumper

5.

Coil spring

6.

Lower rubber seat

7.

Strut

8.

Steering knuckle

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

JPEIA0241GB

1.

Piston rod lock nut

2.

Mounting insulator

3.

Mounting bearing

4.

Bound bumper

5.

Coil spring

6.

Lower rubber seat

7.

Strut

8.

Steering knuckle

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

FSU-10

< REMOVAL AND INSTALLATION >

FRONT COIL SPRING AND STRUT

Removal and Installation

INFOID:0000000006545071

REMOVAL

1.

Remove tires. Refer to

WT-7, "Removal and Installation"

.

2.

Remove lock plate from strut assembly. Refer to

BR-29, "FRONT : Removal and Installation"

(LHD),

BR-

95, "FRONT : Removal and Installation"

(RHD).

3.

Remove wheel sensor. Refer to

BRC-84, "FRONT WHEEL SENSOR : Removal and Installation"

(Without

ESP),

BRC-224, "FRONT WHEEL SENSOR : Removal and Installation"

(With ESP).

4.

Remove stabilizer connecting rod from strut assembly. Refer to

FSU-16, "Removal and Installation"

.

5.

Remove strut mounting bolts and nuts from steering knuckle.

6.

Remove grommet (A) of cowl top cover.

NOTE:
Remove mounting bolt of mounting insulator (1) from grommet
hole.

7.

Remove mounting bolt of mounting insulator, and then remove
strut assembly.

INSTALLATION

Note the following, and install in the reverse order of removal.
• Install strut assembly with the identification mark (A) of mounting

insulator faced forward of the vehicle and the arrow (B) faced out-
side.
NOTE:
The identification mark "0" shows the right mounting insulator and
"1" shows left.

• Never reuse strut mounting nut.
• Perform final tightening of bolts and nuts at the vehicle installation

position (rubber bushing), under unladen conditions with tires on
level ground.

• Perform inspection after installation. Refer to

FSU-12, "Inspection"

.

• After replacing the strut absorber, always follow the disposal pro-

cedure to discard the strut absorber. Refer to

FSU-12, "Disposal"

.

Disassembly and Assembly

INFOID:0000000006545072

DISASSEMBLY

CAUTION:

Never damage strut assembly piston rod when removing components from strut assembly.

1.

Install strut attachment (A) (SST: ST35652000) to strut assem-
bly and secure it in a vise.

CAUTION:

When installing the strut attachment to strut assembly,
wrap a shop cloth around strut to protect from damage.

: Vehicle front

JPEIA0250ZZ

JPEIA0246ZZ

JPEIA0006ZZ

FRONT COIL SPRING AND STRUT

FSU-11

< REMOVAL AND INSTALLATION >

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2.

Using a spring compressor (A) (commercial service tool), com-
press coil spring between spring upper seat and lower seat
(strut assembly) until coil spring with a spring compressor is
free.

CAUTION:

Be sure a spring compressor is securely attached to coil
spring. Compress coil spring.

3.

Check coil spring with a spring compressor between spring
upper seat and lower seat (strut assembly) is free. And then
remove piston rod lock nut while securing the piston rod tip so
that piston rod does not turn.

4.

Remove mounting insulator, mounting bearing, and bound
bumper from strut.

5.

After removing coil spring with a spring compressor, then gradually release a spring compressor.

CAUTION:

Loosen while making sure coil spring attachment position does not move.

6.

Remove lower rubber seat.

7.

Perform inspection after disassembly. Refer to

FSU-12, "Inspection"

.

ASSEMBLY

CAUTION:

Never damage strut assembly piston rod when installing components from strut assembly.
1.

Install strut attachment (SST: ST35652000) to strut and secure it in a vise.

CAUTION:

When installing the strut attachment to strut assembly, wrap a shop cloth around strut to protect
from damage.

2.

Install lower rubber seat.

3.

Compress coil spring using a spring compressor (commercial service tool), and install it onto strut assem-
bly.

CAUTION:

• Be sure a compressor is securely attached to coil spring. Compress coil spring.
• Be careful with the vertical direction of the coil spring.

• Align the lower end of coil spring (1) with (A) of lower rub-

ber seat (2) as shown in the figure.

4.

Apply soapy water to bound bumper.

CAUTION:

Never use machine oil.

5.

Insert bound bumper into mounting insulator.

6.

Install mounting bearing.

CAUTION:

Never apply oils, such as grease, when installing the
mounting bearing.

JPEIA0007ZZ

: Upper side

JPEIA0253ZZ

JPEIA0247ZZ