Juke F15 (2012 year). Service Repair Manual — part 50

BRM-120

< SERVICE DATA AND SPECIFICATIONS (SDS)

BODY ALIGNMENT

Underbody (2WD Models)

INFOID:0000000006482876

MEASUREMENT

Dimensions marked with

″

*

″

indicate symmetrically identical dimensions on both the right and left hand of the

vehicle.
The following figure shows a bottom view and a side view of the vehicle.

JSKIA1991GB

BODY ALIGNMENT

BRM-121

< SERVICE DATA AND SPECIFICATIONS (SDS)

C

D

E

F

G

H

I

J

L

M

A

B

BRM

N

O

P

MEASUREMENT POINTS

Unit: mm (in)

Unit: mm (in)

: Vehicle front

: Vehicle left side

: Vehicle front

Points

Coordinates

Remarks

Points

Coordinates

Remarks

X

Y

Z

X

Y

Z

A

473.5

(18.642)

−

557.0

(

−

21.929)

293.0

(11.535)

Hole

φ

11 (0.43)

H, h

±

482.3

(

±

18.988)

2374.2

(93.472)

348.3

(13.713)

Hole

φ

12 (0.47)

a

−

491.0

(

−

19.331)

−

557.0

(

−

21.929)

301.9

(11.886)

Hole

φ

11 (0.43)

J

499.5

(19.665)

2448.0

(96.378)

378.0

(14.882)

Hole

φ

21 (0.83)

B

472.4

(18.598)

−

455.0

(

−

17.913)

328.9

(12.949)

Hole

φ

18 (0.71)

j

−

487.5

(

−

19.193)

2448.0

(96.378)

378.0

(14.882)

Hole

φ

21 (0.83)

JSKIA2153ZZ

BRM-122

< SERVICE DATA AND SPECIFICATIONS (SDS)

BODY ALIGNMENT

Underbody (4WD Models)

INFOID:0000000006482896

MEASUREMENT

Dimensions marked with

″

*

″

indicate symmetrically identical dimensions on both the right and left hand of the

vehicle.
The following figure shows a bottom view and a side view of the vehicle.

b

−

489.7

(

−

19.279)

−

455.0

(

−

17.913)

328.9

(12.949)

Hole

φ

18 (0.71)

K

498.0

(19.606)

2743.0

(107.992)

378.0

(14.882)

Hole 17

×

16

(0.67

×

0.63)

C, c

±

410.0

(

±

16.142)

547.0

(21.535)

190.2

(7.488)

Hole

φ

16 (0.63)

k

−

487.5

(

−

19.193)

2743.0

(107.992)

378.0

(14.882)

Hole 17

×

16

(0.67

×

0.63)

D, d

±

410.0

(

±

16.142)

815.0

(32.087)

184.0

(7.244)

Hole

φ

12 (0.47)

M

498.0

(19.606)

2970.0

(116.929)

375.4

(14.779)

Hole

φ

16 (0.63)

E, e

±

410.0

(

±

16.142)

1173.0

(46.181)

170.1

(6.697)

Hole 14

×

2

(0.55

×

0.47)

m

−

485.1

(

−

19.098)

2965.8

(116.764)

375.4

(14.779)

Hole

φ

16 (0.63)

F, f

±

633.0

(

±

24.921)

2032.3

(80.012)

318.0

(12.520)

Hole

φ

16 (0.63)

N, n

±

583.6

(

±

22.976)

6.6

(0.261)

868.2

(34.181)

Hole

φ

98 (3.86)

G, g

±

350.0

(

±

13.780)

2253.0

(88.701)

390.4

(15.370)

Hole

†

16 (0.63)

O, o

±

575.4

(

±

22.653)

2569.2

(101.149)

734.4

(28.913)

Hole

φ

20 (0.79)

Points

Coordinates

Remarks

Points

Coordinates

Remarks

X

Y

Z

X

Y

Z

BODY ALIGNMENT

BRM-123

< SERVICE DATA AND SPECIFICATIONS (SDS)

C

D

E

F

G

H

I

J

L

M

A

B

BRM

N

O

P

MEASUREMENT POINTS

Unit: mm (in)

: Vehicle front

: Vehicle left side

JSKIA2154GB

BRM-124

< SERVICE DATA AND SPECIFICATIONS (SDS)

BODY ALIGNMENT

Unit: mm (in)

: Vehicle front

Points

Coordinates

Remarks

Points

Coordinates

Remarks

X

Y

Z

X

Y

Z

A

473.5

(18.642)

−

557.0

(

−

21.929)

293.0

(11.535)

Hole

φ

11 (0.43)

G, g

±

515.1

(

±

20.279)

2318.6

(91.283)

357.2

(14.063)

Hole

φ

12 (0.47)

a

−

491.0

(

−

19.331)

−

557.0

(

−

21.929)

301.9

(11.886)

Hole

φ

11 (0.43)

H, h

±

330.0

(

±

12.992)

2339.7

(92.114)

419.0

(16.496)

Hole 33

×

30

(1.30

×

1.18)

B

472.4

(18.598)

−

455.0

(

−

17.913)

328.9

(12.949)

Hole

φ

18 (0.71)

J, j

±

482.0

(

±

18.976)

2648.0

(104.252)

422.2

(16.622)

Hole 20

×

6

(0.79

×

0.63)

b

−

489.7

(

−

19.279)

−

455.0

(

−

17.913)

328.9

(12.949)

Hole

φ

18 (0.71)

K, k

±

300.0

(

±

11.811)

2815.0

(110.827)

417.2

(16.425)

Hole 18

×

6

(0.71

×

0.63)

C, c

±

410.0

(

±

16.142)

547.0

(21.535)

190.2

(7.488)

Hole

φ

16 (0.63)

M, m

±

482.7

(

±

19.004)

2910.5

(114.586)

421.4

(16.591)

Hole

φ

23 (0.91)

D, d

±

410.0

(

±

16.142)

815.0

(32.087)

184.0

(7.244)

Hole

φ

12 (0.47)

N, n

±

583.6

(

±

22.976)

6.6

(0.261)

868.2

(34.181)

Hole

φ

98 (3.86)

JSKIA2155ZZ

BODY ALIGNMENT

BRM-125

< SERVICE DATA AND SPECIFICATIONS (SDS)

C

D

E

F

G

H

I

J

L

M

A

B

BRM

N

O

P

Passenger Compartment

INFOID:0000000006482877

MEASUREMENT

Dimensions marked with

″

*

″

indicate symmetrically identical dimensions on both the right and left hand of the

vehicle.

«The others»

E, e

±

410.0

(

±

16.142)

1173.0

(46.181)

170.1

(6.697)

Hole 14

×

2

(0.55

×

0.47)

O, o

±

558.8

(

±

22.000)

2568.4

(101.118)

734.4

(28.913)

Hole

φ

20 (0.79)

F, f

±

601.8

(

±

23.693)

2016.4

(79.386)

315.0

(12.402)

Hole

φ

15 (0.59)

Points

Coordinates

Remarks

Points

Coordinates

Remarks

X

Y

Z

X

Y

Z

Unit: mm (in)

JSKIA1996GB

BRM-126

< SERVICE DATA AND SPECIFICATIONS (SDS)

BODY ALIGNMENT

Unit: mm (in)

MEASUREMENT POINTS

Point

Dimension

Memo

Point

Dimension

Memo

Point

Dimension

Memo

Point

Dimension

Memo

A - E

724 (28.50)*

H - h

1406 (55.35)

N - n

1423 (56.02)

R - J

1394 (54.88)*

B - E

1028 (40.47)*

H - j

1829 (72.01)*

N - o

1585 (62.40)*

R - K

1072 (42.20)*

C - d

1290 (50.79)*

H - k

1663 (65.47)*

N - p

1554 (61.18)*

S - M

1094 (43.07)*

C - e

1423 (56.02)*

J - j

1257 (49.49)

N - q

1506 (59.29)*

S - N

786 (30.94)*

F - f

1222 (48.11)

J - k

1463 (57.60)*

O - o

1326 (52.20)

S - O

1248 (49.13)*

F - h

1569 (61.77)*

K - k

1425 (56.10)

O - q

1518 (59.76)*

S - P

1126 (44.33)*

F - j

1386 (54.57)*

M - m

1248 (49.13)

P - p

1397 (55.00)

S - Q

905 (35.63)*

F - k

1519 (59.80)*

M - n

1451 (57.13)*

Q - q

1444 (56.85)

T - V

1128 (44.41)*

G - g

1359 (53.50)

M - o

1441 (56.73)*

R - F

1104 (43.46)*

T - W

1105 (43.50)*

G - j

1630 (64.17)*

M - p

1486 (58.50)*

R - G

885 (34.84)*

U - V

1204 (47.40)*

G - k

1616 (63.62)*

M - q

1578 (62.13)*

R - H

720 (28.35)*

U - W

1091 (42.95)*

JSKIA1997ZZ

BODY ALIGNMENT

BRM-127

< SERVICE DATA AND SPECIFICATIONS (SDS)

C

D

E

F

G

H

I

J

L

M

A

B

BRM

N

O

P

Unit: mm (in)

Rear Body

INFOID:0000000006482880

MEASUREMENT

Dimensions marked with

″

*

″

indicate symmetrically identical dimensions on both the right and left hand of the

vehicle.

MEASUREMENT POINTS

: Vehicle front

Point

Material

Point

Material

A

Cowl top flange end of center positioning mark

J, j, K, k, M, m,
N, n

Center pillar indent

B

Roof flange end of center positioning mark

O, o, Q, q

Rear fender indent

C, c

Outer side body joggle

P, p

Outer rear wheelhouse joggle

D, d, G, g

Upper inner front pillar joggle

R

Trans control reinforcement hole center of center
positioning mark

φ

16 (0.63)

E, e

Hood hinge installing hole center

φ

12 (0.47)

S

Parking brake reinforcement hole center of cen-
ter positioning mark

φ

12 (0.47)

F, f, H, h

Front pillar indent

T, t, U, u, V, v,
W, w

Door hinge installing hole center
T, t, U, u, W, w:

φ

12 (0.47)

V, v:

φ

9 (0.35)

Unit: mm (in)

JSKIA1998GB

BRM-128

< SERVICE DATA AND SPECIFICATIONS (SDS)

BODY ALIGNMENT

: Vehicle front

JSKIA1999ZZ

Point

Material

Point

Material

A

Roof flange end of center positioning mark

C, c, D, d

Rear combination lamp base joggle

B, b

Rear fender extension joggle

E

Upper rear panel indent of center positioning
mark

LOCATION OF PLASTIC PARTS

BRM-129

< SERVICE DATA AND SPECIFICATIONS (SDS)

C

D

E

F

G

H

I

J

L

M

A

B

BRM

N

O

P

LOCATION OF PLASTIC PARTS

Precautions for Plastics

INFOID:0000000006698764

CAUTION:

• When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence of heat

and solvent) and remove them if necessary or take suitable measures to protect them.

• Plastic parts should be repaired and painted using methods suiting the materials

,

characteristics.

Abbre-

viation

Material name

Heat resisting

temperature

°

C (

°

F)

Resistance to gasoline and

solvents

Other cautions

PE

Polyethylene

60 (140)

Gasoline and most solvents are
harmless if applied for a very
short time (wipe out quickly).

Flammable

ABS

Acrylonitrile Butadiene Styrene

80 (176)

Avoid gasoline and solvents.

—

EPM/
EPDM

Ethylene Propylene (Diene) co-
polymer

80 (176)

Gasoline and most solvents are
harmless if applied for a very
short time (wipe out quickly).

Flammable

PS

Polystyrene

80 (176)

Avoid solvents.

Flammable

PVC

Poly Vinyl Chloride

80 (176)

Gasoline and most solvents are
harmless if applied for a very
short time (wipe out quickly).

Poisonous gas is emitted
when burned.

TPO

Thermoplastic Olefine

80 (176)

↑

Flammable

AAS

Acrylonitrile Acrylic Styrene

85 (185)

Avoid gasoline and solvents.

—

PMMA

Poly Methyl Methacrylate

85 (185)

↑

—

EVAC

Ethylene Vinyl Acetate

90 (194)

↑

—

PP

Polypropylene

90 (194)

Gasoline and most solvents are
harmless if applied for a very
short time (wipe out quickly).

Flammable, avoid bat-
tery acid.

PUR

Polyurethane

90 (194)

Avoid gasoline and solvents.

—

UP

Unsaturated Polyester

90 (194)

↑

Flammable

ASA

Acrylonitrile Styrene Acrylate

100 (212)

↑

Flammable

PPE

Poly Phenylene Ether

110 (230)

↑

—

TPU

Thermoplastic Urethane

110 (230)

↑

—

PBT+
PC

Poly Butylene Terephthalate +
Polycarbonate

120 (248)

↑

Flammable

PC

Polycarbonate

120 (248)

↑

—

POM

Poly Oxymethylene

120 (248)

↑

Avoid battery acid.

PA

Polyamide

140 (284)

↑

Avoid immersing in wa-
ter.

PBT

Poly Butylene Terephthalate

140 (284)

↑

—

PAR

Polyarylate

180 (356)

↑

—

PET

Polyethylene terephthalate

180 (356)

↑

—

PEI

Polyetherimide

200 (392)

↑

—

BRM-130

< SERVICE DATA AND SPECIFICATIONS (SDS)

LOCATION OF PLASTIC PARTS

Location of Plastic Parts

INFOID:0000000006482882

Component

Material

Component

Material

1

Windshield molding

PVC

10

Door outside molding

PVC + Stainless

2

Front combination lamp

Lens

PMMA

11

Door outside handle

Front

PC + PET

Housing

PP

Rear

PC + PET +

Glass fiber

3

Front grille

ABS

12

Rear combination lamp

Lens

PMMA

4

Bumper fascia

PP + EPM

Housing

ASA

5

Head lamp

Lens

PC

13

High mount stop lamp

Lens

PMMA

Housing

PP

Housing

PC + ABS

6

Fillet molding

PP + EPM

14

Back door finisher

ABS

7

Front fender protector

PP

15

License plate lamp
(2WD Models)

Lens

PC

8

Side turn signal lamp

Lens

PMMA

Housing

PBT

Housing

PC + ABS

License plate lamp
(4WD Models)

Lens

PC

9

Door outside
mirror

Housing

ASA

Housing

PC

Base

PBT + PET +

Glass fiber

16

Reflex reflector

Lens

PMMA

Cover

Material color

ASA

Housing

ABS

Body color

ABS

17

Center mudguard

PP + EPM

JSKIA2000ZZ

LOCATION OF PLASTIC PARTS

BRM-131

< SERVICE DATA AND SPECIFICATIONS (SDS)

C

D

E

F

G

H

I

J

L

M

A

B

BRM

N

O

P

JSKIA2001ZZ

Component

Material

Component

Material

1

Rear pillar finisher

PP

6

Cluster lid C

PC + ABS

2

Center pillar garnish

PP

7

Instrument panel

PP

3

Map lamp

Lens

PC

8

Glove box

PP

Housing

PA

9

Multi display unit

Lens

PC

4

Front pillar garnish

PP

Finisher

PC + ABS

5

Cluster lid A

PP

10

Center console

PP

CCS-1

CRUISE CONTROL & DRIVER ASSISTANCE

C

D

E

F

G

H

I

J

K

L

M

B

CCS

SECTION

CCS

N

P

A

CONTENTS

CRUISE CONTROL SYSTEM

ASCD

SYSTEM DESCRIPTION . . . . . . . ..

2

AUTOMATIC SPEED CONTROL DEVICE
(ASCD) . . . . . . . . . . . . . . . ...

2

Information . . . . . . . . . . . . . . . ....

2

CCS-2

< SYSTEM DESCRIPTION >

[ASCD]

AUTOMATIC SPEED CONTROL DEVICE (ASCD)

SYSTEM DESCRIPTION

AUTOMATIC SPEED CONTROL DEVICE (ASCD)

Information

INFOID:0000000006484156

Automatic Speed Control Device (ASCD) system is controlled by ECM.
Regarding the information for ASCD system, refer to

EC-64, "AUTOMATIC SPEED CONTROL DEVICE

(ASCD) : System Description"

.

CHG

CHG-1

ELECTRICAL & POWER CONTROL

C

D

E

F

G

H

I

J

K

L

B

SECTION

CHG

A

O

P

N

CONTENTS

CHARGING SYSTEM

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

3

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

3

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

3

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

3

Precaution for Power Generation Voltage Variable
Control System . . . . . . . . . . . . . . ..

4

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

5

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

5

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

5

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

5

SYSTEM DESCRIPTION . . . . . . . ..

6

COMPONENT PARTS . . . . . . . . . .

6

CHARGING SYSTEM . . . . . . . . . . . . ..

6

CHARGING SYSTEM : Component Parts Loca-
tion . . . . . . . . . . . . . . . . . . ....

6

CHARGING SYSTEM : Component Description . ..

6

POWER GENERATION VOLTAGE VARIABLE
CONTROL SYSTEM . . . . . . . . . . . . ....

6

POWER GENERATION VOLTAGE VARIABLE
CONTROL SYSTEM : Component Parts Location

. ..

6

POWER GENERATION VOLTAGE VARIABLE
CONTROL SYSTEM : Component Description . ....

7

SYSTEM . . . . . . . . . . . . . . . ..

8

CHARGING SYSTEM . . . . . . . . . . . . ..

8

CHARGING SYSTEM : System Diagram . . . .....

8

CHARGING SYSTEM : System Description . . .....

9

POWER GENERATION VOLTAGE VARIABLE
CONTROL SYSTEM . . . . . . . . . . . . ....

9

POWER GENERATION VOLTAGE VARIABLE
CONTROL SYSTEM : System Diagram (Gasoline
Engine Models) . . . . . . . . . . . . . . .

9

POWER GENERATION VOLTAGE VARIABLE
CONTROL SYSTEM : System Description (Gaso-
line Engine Models) . . . . . . . . . . . . ..

9

WIRING DIAGRAM . . . . . . . . . ..

10

CHARGING SYSTEM . . . . . . . . . ...

10

Wiring Diagram . . . . . . . . . . . . . .

10

BASIC INSPECTION . . . . . . . . ...

12

DIAGNOSIS AND REPAIR WORKFLOW . .

12

GASOLINE ENGINE MODELS . . . . . . . . ..

12

GASOLINE ENGINE MODELS : Work Flow . . ...

12

DIESEL ENGINE MODELS . . . . . . . . . ...

14

DIESEL ENGINE MODELS : Work Flow . . . . .

15

CHARGING SYSTEM PRELIMINARY IN-
SPECTION . . . . . . . . . . . . . .

17

Inspection Procedure . . . . . . . . . . . ...

17

POWER GENERATION VOLTAGE VARI-
ABLE CONTROL SYSTEM OPERATION IN-
SPECTION . . . . . . . . . . . . . .

18

Inspection Procedure . . . . . . . . . . . ...

18

DTC/CIRCUIT DIAGNOSIS . . . . . . .

20

B TERMINAL CIRCUIT . . . . . . . . . .

20

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

20

Diagnosis Procedure . . . . . . . . . . . ...

20

L TERMINAL CIRCUIT (OPEN) . . . . . .

21

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

21

Diagnosis Procedure . . . . . . . . . . . ...

21

L TERMINAL CIRCUIT (SHORT) . . . . . .

23

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

23

CHG-2

Diagnosis Procedure . . . . . . . . . . . ..

23

S TERMINAL CIRCUIT . . . . . . . . . ..

24

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

24

Diagnosis Procedure . . . . . . . . . . . ..

24

SYMPTOM DIAGNOSIS . . . . . . . .

25

CHARGING SYSTEM . . . . . . . . . .

25

Symptom Table . . . . . . . . . . . . . ..

25

REMOVAL AND INSTALLATION . . . ...

26

ALTERNATOR . . . . . . . . . . . . ...

26

HR16DE . . . . . . . . . . . . . . . . . .

26

HR16DE : Exploded View . . . . . . . . . ...

26

HR16DE : Removal and Installation . . . . . ...

27

HR16DE : Disassembly and Assembly . . . . ...

28

HR16DE : Inspection . . . . . . . . . . . ..

29

MR16DDT . . . . . . . . . . . . . . . . ..

30

MR16DDT : Exploded View . . . . . . . . .

30

MR16DDT : Removal and Installation . . . . . .

31

MR16DDT : Disassembly and Assembly . . . .

32

MR16DDT : Inspection . . . . . . . . . . .

33

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

35

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

35

Alternator . . . . . . . . . . . . . . . .

35