Nissan Juke (2012 year). Service Repair Manual — part 40
CLUTCH MASTER CYLINDER
CL-13
< REMOVAL AND INSTALLATION >
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CLUTCH MASTER CYLINDER
Exploded View
INFOID:0000000007576615
Removal and Installation
INFOID:0000000007576616
REMOVAL
CAUTION:
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• Never disassemble clutch master cylinder.
1.
Drain clutch fluid. Refer to
.
2.
Remove air cleaner case. Refer to
EM-25, "Removal and Installation"
.
3.
Remove reservoir hose from reservoir tank and master cylinder.
4.
Remove master cylinder rod end (
) from clutch pedal.
5.
Pull up the lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3).
6.
Rotate master cylinder clockwise by 45 degrees, and then
remove master cylinder from the vehicle.
1.
Reservoir hose
2.
Reservoir tank
3.
Master cylinder
JPDIB0162ZZ
PCIB1491E
JPDIB0167ZZ
Revision: 2011 October
2012 JUKE
CL-14
< REMOVAL AND INSTALLATION >
CLUTCH MASTER CYLINDER
INSTALLATION
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
1.
Tilt master cylinder clockwise by 45 degrees (A) and insert it to
the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple (1) is upward of the vehicle.
2.
Install master cylinder rod end to clutch pedal.
CAUTION:
Press master cylinder rod end into clutch pedal until it
stops.
3.
Install reservoir hose to reservoir tank and master cylinder.
CAUTION:
Set reservoir hose with painted mark facing upward.
4.
Press down the lock pin into connector of master cylinder until it stops.
5.
Install clutch tube into connector of master cylinder until it stops.
6.
For the next step and after, install in the reverse order of removal.
Inspection and Adjustment
INFOID:0000000007576617
INSPECTION AFTER INSTALLATION
• Check the fluid leakage and the fluid level. Refer to
.
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-6, "Inspection and Adjustment"
• Check the clutch interlock switch position. Refer to
CL-6, "Inspection and Adjustment"
.
• Check the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)
CL-6, "Inspection and Adjustment"
.
ADJUSTMENT AFTER INSTALLATION
• Adjust the clutch interlock switch position. Refer to
CL-6, "Inspection and Adjustment"
.
• Adjust the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)
CL-6, "Inspection and Adjustment"
.
• Perform the air bleeding. Refer to
B
: Mounting condition
JPDIB0114ZZ
Revision: 2011 October
2012 JUKE
CLUTCH PIPING
CL-15
< REMOVAL AND INSTALLATION >
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CLUTCH PIPING
Exploded View
INFOID:0000000007576618
Hydraulic Layout
INFOID:0000000007576619
Removal and Installation
INFOID:0000000007576620
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
Note the following, and refer to
• Drain clutch fluid. Refer to
.
1.
CSC (Concentric Slave Cylinder)
2.
Clutch tube
3.
Clutch damper
4.
Bracket
5.
Master cylinder
JPDIB0184ZZ
1.
Clutch tube
2.
Lock pin
3.
CSC (Concentric Slave Cylinder)
4.
Clutch damper
5.
Master cylinder
6.
Clutch pedal
PCIB1499E
Revision: 2011 October
2012 JUKE
CL-16
< REMOVAL AND INSTALLATION >
CLUTCH PIPING
• Press the lock pin into the bleeding connector of the CSC, and then remove clutch tube from CSC.
• Pull the lock pins from the connectors of the clutch damper until the pins stop, and then remove clutch tubes
from clutch damper.
• Pull the lock pin from the connector of the clutch master cylinder until the pin stop, and then remove clutch
tube from clutch master cylinder.
INSTALLATION
Note the following, and refer to
for installation procedure.
CAUTION:
Never damage clutch tube.
• Insert each clutch tube into the CSC bleeding connector, the clutch damper connector, and the clutch master
cylinder connector until it contacts the end of each connector.
• Install each lock pin into the clutch damper connector and the clutch master cylinder connector until it con-
tacts the end of each connector.
Inspection and Adjustment
INFOID:0000000007576621
INSPECTION AFTER REMOVAL
• Check the clutch tube for cracks and damage. If the clutch tube has cracks or damage, replace it with a new
one.
• Check the O-ring of the clutch tube for cracks and damage. If the O-ring of the clutch tube has cracks or
damage, replace clutch tube with a new one.
• Check the clutch damper for cracks and damage. If the clutch damper has cracks or damage, replace it with
a new one.
INSPECTION AFTER INSTALLATION
• Check the fluid leakage and the fluid level. Refer to
.
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-6, "Inspection and Adjustment"
ADJUSTMENT AFTER INSTALLATION
Perform the air bleeding. Refer to
Revision: 2011 October
2012 JUKE
CSC (CONCENTRIC SLAVE CYLINDER)
CL-17
< UNIT REMOVAL AND INSTALLATION >
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UNIT REMOVAL AND INSTALLATION
CSC (CONCENTRIC SLAVE CYLINDER)
Exploded View
INFOID:0000000007576622
Removal and Installation
INFOID:0000000007576623
CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage.
• Never disassemble CSC.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
1.
Remove transaxle assembly. Refer to
TM-25, "Removal and Installation"
2.
Remove CSC from clutch housing.
INSTALLATION
1.
Install CSC to clutch housing, and then tighten CSC mounting bolts to the specified torque.
CAUTION:
• Never reuse CSC.
• Never insert and operate CSC because piston and stopper of CSC components may fall off.
2.
For the next step and after, install in the reverse order of removal.
Inspection and Adjustment
INFOID:0000000007576624
INSPECTION AFTER INSTALLATION
Check the fluid leakage and the fluid level. Refer to
.
ADJUSTMENT AFTER INSTALLATION
Perform the air bleeding. Refer to
1.
Transaxle assembly
2.
CSC (Concentric Slave Cylinder)
: Always replace after every disassembly.
: N·m (kg-m, ft-lb)
JPDIB0040GB
Revision: 2011 October
2012 JUKE
CL-18
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
CLUTCH DISC AND CLUTCH COVER
Exploded View
INFOID:0000000007576625
Removal and Installation
INFOID:0000000007576626
CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage. Refer to
CL-17, "Removal and Installation"
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• Never clean clutch disc using solvent.
REMOVAL
1.
Remove transaxle assembly. Refer to
TM-25, "Removal and Installation"
2.
Remove clutch cover mounting bolts while holding clutch cover.
CAUTION:
Never drop clutch disc.
3.
Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
INSTALLATION
1.
Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
1.
Flywheel
2.
Clutch disc
3.
Clutch cover
4.
Input shaft
A.
First step
B.
Final step
: N·m (kg-m, ft-lb)
: Apply lithium-based grease including molybdenum disulphide.
JPDIB0049GB
Revision: 2011 October
2012 JUKE
CLUTCH DISC AND CLUTCH COVER
CL-19
< UNIT REMOVAL AND INSTALLATION >
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2.
Apply recommended grease to clutch disc (1) and input shaft (2)
splines (A).
CAUTION:
Be sure to apply grease to the points specified. Otherwise,
noise, poor disengagement, or damage to the clutch may
result. Excessive grease may cause slip or judder. And if it
adheres to seal of CSC, it cause clutch fluid leakage. Wipe
out excess grease. Wipe out any grease oozing from the
parts.
3.
Install clutch disc, using a clutch aligner (A) [Commercial service
tool].
4.
Install clutch cover, and then temporarily tighten clutch cover
mounting bolts.
5.
Tighten clutch cover mounting bolts to the specified torque
evenly in two steps in the numerical order as shown in the fig-
ure.
6.
For the next step and after, install in the reverse order of
removal.
Inspection
INFOID:0000000007576627
INSPECTION AFTER REMOVAL
Clutch Disc
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If it is outside the specification,
replace clutch disc.
• Measure the depth “A” to clutch disc facing rivet heads, using a
calipers. If it exceeds the allowable wear limit, replace clutch disc.
Clutch Cover
• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
• Broken thrust ring will make a clinking sound when cover is shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.
JPDIB0239ZZ
PCIB1503E
Runout limit/diameter of the area
to be measured
: Refer to
Maximum allowable spline back-
lash (at outer edge of disc)
: Refer to
Facing wear limit (depth to the
rivet head) “A”
: Refer to
SCL221
JPDIB0026ZZ
Revision: 2011 October
2012 JUKE
CL-20
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
INSPECTION AFTER INSTALLATION
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height,
using the diaphragm adjusting wrench (A) [SST: ST20050240 ( - )].
Tolerance for diaphragm spring
lever unevenness
: Refer to
JPDIB0160ZZ
Revision: 2011 October
2012 JUKE
SERVICE DATA AND SPECIFICATIONS (SDS)
CL-21
< SERVICE DATA AND SPECIFICATIONS (SDS)
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SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
INFOID:0000000007576628
Unit: mm (in)
Clutch Pedal
INFOID:0000000007576629
Unit: mm (in)
*: With ASCD or with push-button ignition switch system
Clutch Disc
INFOID:0000000007576630
Unit: mm (in)
Clutch Cover
INFOID:0000000007576631
Unit: mm (in)
Engine type
MR16DDT
Transaxle type
RS6F94R
Type of clutch control
Hydraulic
Clutch disc
Facing size (Outer dia.
×
Inner dia.
×
Thickness)
230
×
155
×
3.2
(9.06
×
6.10
×
0.126)
Recommended clutch fluid
MA-10, "Fluids and Lubricants"
.
Engine type
MR16DDT
Transaxle type
RS6F94R
Clutch pedal height
169.7 – 179.7 (6.68 – 7.07)
Clutch pedal height at clutch disengagement
80 (3.15) or more
Clutch pedal play
[Looseness at clutch pedal pin]
2 – 8 (0.08 – 0.31)
[0 – 1.3 (0 – 0.051)]
Clearance between stopper rubber and clutch interlock switch threaded
end while clutch pedal is fully depressed.
0.74 – 1.96 (0.0291 – 0.0772)
Clearance between clutch pedal and clutch pedal position switch thread-
ed end while clutch pedal is fully released.
*
0.74 – 1.96 (0.0291 – 0.0772)
Engine type
MR16DDT
Transaxle type
RS6F94R
Runout limit/diameter of the area to be measured
1.0 (0.039) / 220 (8.66) dia.
Maximum allowable spline backlash (at outer edge of disc)
0.9 (0.035)
Facing wear limit (depth to the rivet head)
0.35 (0.0138)
Engine type
MR16DDT
Transaxle type
RS6F94R
Tolerance for diaphragm spring lever unevenness
0.7 (0.028) or less
Revision: 2011 October
2012 JUKE
CO-1
ENGINE
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SECTION
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CONTENTS
ENGINE COOLING SYSTEM
MR16DDT
PRECAUTION . . . . . . . . . . . ...
PRECAUTIONS . . . . . . . . . . . . ...
PREPARATION . . . . . . . . . . .
PREPARATION . . . . . . . . . . . . ...
Commercial Service Tools . . . . . . . . . ...
SYSTEM DESCRIPTION . . . . . . . ..
DESCRIPTION . . . . . . . . . . . . .
Engine Cooling System . . . . . . . . . . .....
Engine Cooling System Schematic . . . . . . ...
SYMPTOM DIAGNOSIS . . . . . . . ...
OVERHEATING CAUSE ANALYSIS . . . . ..
Troubleshooting Chart . . . . . . . . . . . ...
PERIODIC MAINTENANCE . . . . . . ..
ENGINE COOLANT . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . ..
Draining . . . . . . . . . . . . . . . . .....
Refilling . . . . . . . . . . . . . . . . .....
Flushing . . . . . . . . . . . . . . . . ...
RADIATOR . . . . . . . . . . . . . . .
RADIATOR CAP . . . . . . . . . . . . . .
RADIATOR CAP : Inspection . . . . . . . . ..
RADIATOR . . . . . . . . . . . . . . . .
RADIATOR : Inspection . . . . . . . . . . ..
REMOVAL AND INSTALLATION . . . ...
RADIATOR . . . . . . . . . . . . . .
Exploded View . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . .
COOLING FAN . . . . . . . . . . . . ..
Exploded View . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . .
Disassembly and Assembly . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . .
WATER PUMP . . . . . . . . . . . . ..
Exploded View . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . .
THERMOSTAT . . . . . . . . . . . . ..
Exploded View . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . .
WATER OUTLET . . . . . . . . . . . ..
Exploded View . . . . . . . . . . . . . . .
Removal and Installation . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . .
SERVICE DATA AND SPECIFICATIONS
(SDS) . . . . . . . . . . . . . . .
SERVICE DATA AND SPECIFICATIONS
(SDS) . . . . . . . . . . . . . . . . .
Periodical Maintenance Specification . . . . . ..
Radiator . . . . . . . . . . . . . . . . ...
Thermostat . . . . . . . . . . . . . . . ..
Water Control Valve . . . . . . . . . . . .
Revision: 2011 October
2012 JUKE
CO-2
< PRECAUTION >
[MR16DDT ]
PRECAUTIONS
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER"
INFOID:0000000007579986
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this
Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that 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 “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never 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.
Revision: 2011 October
2012 JUKE
PREPARATION
CO-3
< PREPARATION >
[MR16DDT ]
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PREPARATION
PREPARATION
Commercial Service Tools
INFOID:0000000007579987
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
Revision: 2011 October
2012 JUKE
CO-4
< SYSTEM DESCRIPTION >
[MR16DDT ]
DESCRIPTION
SYSTEM DESCRIPTION
DESCRIPTION
Engine Cooling System
INFOID:0000000007579988
M/T models
CVT models
JPBIA4333GB
JPBIA4372GB
Revision: 2011 October
2012 JUKE
DESCRIPTION
CO-5
< SYSTEM DESCRIPTION >
[MR16DDT ]
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Engine Cooling System Schematic
INFOID:0000000007579989
M/T models
CVT models
JPBIA4335GB
JPBIA4334GB
Revision: 2011 October
2012 JUKE
CO-6
< SYMPTOM DIAGNOSIS >
[MR16DDT ]
OVERHEATING CAUSE ANALYSIS
SYMPTOM DIAGNOSIS
OVERHEATING CAUSE ANALYSIS
Troubleshooting Chart
INFOID:0000000007579990
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
Revision: 2011 October
2012 JUKE
OVERHEATING CAUSE ANALYSIS
CO-7
< SYMPTOM DIAGNOSIS >
[MR16DDT ]
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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
Revision: 2011 October
2012 JUKE
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