Juke F15 (2012 year). Service Repair Manual - part 55

CL-32

< UNIT REMOVAL AND INSTALLATION >

CLUTCH DISC AND CLUTCH COVER

K9K : Exploded View

INFOID:0000000006404949

K9K : Removal and Installation

INFOID:0000000006404950

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-27, "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-86, "K9K : 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 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)

 : N·m (kg-m, in-lb)

JPDIB0238GB

CLUTCH DISC AND CLUTCH COVER

CL-33

< UNIT REMOVAL AND INSTALLATION >

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2.

Install clutch disc, using a clutch aligner (A) [Commercial service
tool].

3.

Install clutch cover, and then temporarily tighten clutch cover
mounting bolts.

4.

Tighten clutch cover mounting bolts to the specified torque
evenly in two steps in the numerical order as shown in the fig-
ure.

5.

For the next step and after, install in the reverse order of
removal.

K9K : Inspection

INFOID:0000000006413959

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.

INSPECTION AFTER INSTALLATION

Clutch Cover

JPDIB0141ZZ

Runout limit/diameter of the area 
to be measured

: Refer to 

CL-35, 

"Clutch Disc"

.

Maximum allowable spline back-
lash (at outer edge of disc)

: Refer to 

CL-35, 

"Clutch Disc"

.

Facing wear limit (depth to the 
rivet head) “A”

: Refer to 

CL-35, 

"Clutch Disc"

.

SCL221

JPDIB0026ZZ

CL-34

< UNIT REMOVAL AND INSTALLATION >

CLUTCH DISC AND 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 

CL-36, 

"Clutch Cover"

.

JPDIB0160ZZ

SERVICE DATA AND SPECIFICATIONS (SDS)

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< SERVICE DATA AND SPECIFICATIONS (SDS) 

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SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications

INFOID:0000000006404952

Unit: mm (in)

Clutch Pedal

INFOID:0000000006404953

Unit: mm (in)

*1 : With push-button ignition switch system

*2 : With ASCD or with push-button ignition switch system

Clutch Disc

INFOID:0000000006404954

Unit: mm (in)

Engine type

HR16DE

MR16DDT

K9K

Transaxle type

RS5F92R

RS6F94R

Type of clutch control

Hydraulic

Clutch disc

Facing size (Outer dia. 

×

 Inner 

dia. 

×

 Thickness)

215 

×

 140 

×

 3.2

(8.46 

×

 5.51 

×

 0.126)

230 

×

 155 

×

 3.2

(9.06 

×

 6.10 

×

 0.126)

225 

×

 150 

×

 3.1

(8.86 

×

 5.91 

×

 0.122)

Recommended clutch fluid

Refer to 

MA-13, "Fluids and Lubricants"

.

Engine type

HR16DE

MR16DDT

K9K

Transaxle type

RS5F92R

RS6F94R

Handle

LHD

RHD

LHD

RHD

LHD

RHD

Clutch pedal height

162.9 – 172.9

(6.41 – 6.81)

168.1 – 178.1

(6.62 – 7.01)

169.7 – 179.7

(6.68 – 7.07)

178.2 – 188.2

(7.02 – 7.41)

169.7 – 179.7

(6.68 – 7.07)

178.2 – 188.2

(7.02 – 7.41)

Clutch pedal height at clutch disen-
gagement

80 (3.15) or 

more

90 (3.54) or 

more

80 (3.15) or 

more

90 (3.54) or 

more

80 (3.15) or 

more

90 (3.54) 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 de-

pressed. (For LHD) 

*1

0.74 – 1.96 (0.0291 – 0.0772)

Clearance between clutch pedal and 
clutch interlock switch threaded end 
while clutch pedal is fully depressed. 

(For RHD) 

*1

Clearance between clutch pedal and 
clutch pedal position switch threaded 
end while clutch pedal is fully re-

leased.

*2

0.74 – 1.96 (0.0291 – 0.0772)

Engine type

HR16DE

MR16DDT

K9K

Transaxle type

RS5F92R

RS6F94R

Runout limit/diameter of the area to be mea-
sured

1.0 (0.039) / 205 (8.07) dia.

1.0 (0.039) / 220 (8.66) dia.

1.0 (0.039) / 215 (8.46) dia.

Maximum allowable spline backlash (at outer 
edge of disc)

0.9 (0.035)

0.507 (0.0200)

Facing wear limit (depth to the rivet head)

0.3 (0.012)

0.35 (0.0138)

1.0 (0.039)

CL-36

< SERVICE DATA AND SPECIFICATIONS (SDS) 

SERVICE DATA AND SPECIFICATIONS (SDS)

Clutch Cover

INFOID:0000000006404955

Unit: mm (in)

Engine type

HR16DE

MR16DDT

K9K

Transaxle type

RS5F92R

RS6F94R

Tolerance for diaphragm spring lever uneven-
ness

0.7 (0.028) or less

1.2 (0.047) or less

CO-1

ENGINE

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SECTION 

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CONTENTS

ENGINE COOLING SYSTEM

MR16DDT 

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

4

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

4

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

4

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

4

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

6

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

6

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

6

SYSTEM DESCRIPTION  ..............................

7

DESCRIPTION ....................................................

7

Engine Cooling System .............................................

7

Engine Cooling System Schematic  ...........................

8

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

9

OVERHEATING CAUSE ANALYSIS  ..................

9

Troubleshooting Chart ...............................................

9

PERIODIC MAINTENANCE .........................

11

ENGINE COOLANT  ...........................................

11

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

11

Draining ...................................................................

11

Refilling ...................................................................

12

Flushing ...................................................................

13

RADIATOR .........................................................

15

RADIATOR CAP ........................................................

15

RADIATOR CAP : Inspection ..................................

15

RADIATOR ................................................................

15

RADIATOR : Inspection  ..........................................

15

REMOVAL AND INSTALLATION  ...............

17

RADIATOR ........................................................

17

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

17

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

17

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

19

COOLING FAN ..................................................

20

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

20

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

20

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

20

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

21

WATER PUMP  ..................................................

22

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

22

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

22

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

22

THERMOSTAT ..................................................

24

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

24

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

24

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

25

WATER OUTLET  ..............................................

26

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

26

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

26

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

27

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

29

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

29

Periodical Maintenance Specification ......................

29

Radiator ...................................................................

29

Thermostat ..............................................................

29

Water Control Valve  ................................................

29

HR16DE

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

30

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

30

CO-2

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

30

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

30

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

32

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

32

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

32

SYSTEM DESCRIPTION  ............................

33

DESCRIPTION ...................................................

33

Engine Cooling System  ..........................................

33

Engine Cooling System Schematic  ........................

34

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

35

OVERHEATING CAUSE ANALYSIS  ................

35

Troubleshooting Chart  ............................................

35

PERIODIC MAINTENANCE ........................

37

ENGINE COOLANT  ...........................................

37

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

37

Draining ..................................................................

37

Refilling ...................................................................

38

Flushing ..................................................................

39

RADIATOR ........................................................

40

RADIATOR CAP  .......................................................

40

RADIATOR CAP : Inspection  .................................

40

RADIATOR ................................................................

40

RADIATOR : Inspection ..........................................

40

REMOVAL AND INSTALLATION ...............

42

RADIATOR ........................................................

42

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

42

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

42

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

45

COOLING FAN  ..................................................

46

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

46

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

46

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

47

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

47

WATER PUMP  ...................................................

48

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

48

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

48

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

49

THERMOSTAT ..................................................

50

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

50

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

50

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

51

WATER OUTLET  ...............................................

52

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

52

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

52

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

52

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

54

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

54

Periodical Maintenance Specification  .....................

54

Radiator ..................................................................

54

Thermostat ..............................................................

54

Heater Thermostat (CVT models) ...........................

54

Water Control Valve ................................................

54

K9K

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

55

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

55

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

55

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

55

Precaution for Liquid Gasket ...................................

56

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

57

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

57

Special Service Tool  ...............................................

57

SYSTEM DESCRIPTION  ...........................

58

COOLING SYSTEM ...........................................

58

Cooling Circuit .........................................................

58

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

59

RADIATOR ........................................................

59

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

59

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

60

OVERHEATING CAUSE ANALYSIS  ................

60

Troubleshooting Chart  ............................................

60

PERIODIC MAINTENANCE  .......................

62

ENGINE COOLANT ...........................................

62

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

62

Draining ...................................................................

62

Refilling ...................................................................

63

Flushing ..................................................................

63

RESERVOIR TANK CAP  ..................................

65

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

65

REMOVAL AND INSTALLATION ..............

66

RADIATOR ........................................................

66

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

66

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

66

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COOLING FAN  ...................................................

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

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

68

WATER PUMP  ...................................................

70

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

70

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

70

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

70

THERMO PLUNGER UNIT  ................................

72

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

72

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

72

THERMOSTAT ...................................................

74

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

74

WATER OUTLET  ..............................................

75

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

75

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

75

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

76

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

76

Periodical Maintenance Specification ......................

76

Radiator ...................................................................

76

Thermostat ..............................................................

76

CO-4

< PRECAUTION >

[MR16DDT ]

PRECAUTIONS

PRECAUTION

PRECAUTIONS

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

INFOID:0000000006628091

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:0000000006628096

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

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< PRECAUTION >

[MR16DDT ]

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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.

CO-6

< PREPARATION >

[MR16DDT ]

PREPARATION

PREPARATION

PREPARATION

Commercial Service Tools

INFOID:0000000006356311

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

DESCRIPTION

CO-7

< SYSTEM DESCRIPTION >

[MR16DDT ]

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SYSTEM DESCRIPTION

DESCRIPTION

Engine Cooling System

INFOID:0000000006356312

M/T models

CVT models

JPBIA4333GB

JPBIA4372GB

CO-8

< SYSTEM DESCRIPTION >

[MR16DDT ]

DESCRIPTION

Engine Cooling System Schematic

INFOID:0000000006356313

M/T models

CVT models

JPBIA4335GB

JPBIA4334GB

OVERHEATING CAUSE ANALYSIS

CO-9

< SYMPTOM DIAGNOSIS >

[MR16DDT ]

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SYMPTOM DIAGNOSIS

OVERHEATING CAUSE ANALYSIS

Troubleshooting Chart

INFOID:0000000006356314

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

CO-10

< SYMPTOM DIAGNOSIS >

[MR16DDT ]

OVERHEATING CAUSE ANALYSIS

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

ENGINE COOLANT

CO-11

< PERIODIC MAINTENANCE >

[MR16DDT ]

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PERIODIC MAINTENANCE

ENGINE COOLANT

Inspection

INFOID:0000000006356315

LEVEL 

• Check that the reservoir tank engine coolant level is within the

“MIN” to “MAX” when the engine is cool.

• Adjust the engine coolant level if necessary.

LEAKAGE

• To check for leakage, apply pressure to the cooling system with the

radiator cap tester (commercial service tool) (A) and the radiator
cap tester adapter (commercial service tool) (B).

WARNING:

Never remove radiator cap when engine is hot. Serious burns
may occur from high-pressure engine coolant escaping from
radiator.

CAUTION:

Higher test pressure than specified may cause radiator dam-
age.
NOTE:
In a case that engine coolant decreases, replenish radiator with engine coolant.

• If anything is found, repair or replace damaged parts.

Draining

INFOID:0000000006356316

WARNING:

• Never remove radiator cap when engine is hot. Serious burns may occur from high-pressure engine

coolant escaping from radiator. 

• Wrap a thick cloth around the radiator cap. Slowly turn it a quarter of a turn to release built-up pres-

sure. Then turn it all the way.

1.

Connect drain hose.
• Use a genera-purpose hose with the dimensions show in the

figure.

A

:  MAX

B

:  MIN

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Testing pressure: Refer to 

CO-29, "Radiator"

.

PBIC5121J

A

: 

φ

 8  mm

B

: 300 mm

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